Volume 8_Mechanical and Electrical Services

Volume 8 – Mechanical and Electrical Services

Jabatan Pengairan dan Saliran Malaysia Jalan Sultan Salahuddin 50626 KUALA LUMPUR

GOVERNMENT OF MALAYSIA DEPARTMENT OF IRRIGATION

AND DRAINAGE

DID MANUAL VOLUME 8

March 2009 i

Disclaimer

Every effort and care has been taken in selecting methods and recommendations that are appropriate to Malaysian conditions. Notwithstanding these efforts, no warranty or guarantee, express, implied or statutory is made as to the accuracy, reliability, suitability or results of the methods or recommendations. The use of this Manual requires professional interpretation and judgment. Appropriate design procedures and assessment must be applied, to suit the particular circumstances under consideration. The government shall have no liability or responsibility to the user or any other person or entity with respect to any liability, loss or damage caused or alleged to be caused, directly or indirectly, by the adoption and use of the methods and recommendations of this Manual, including but not limited to, any interruption of service, loss of business or anticipatory profits, or consequential damages resulting from the use of this Manual.

DID MANUAL VOLUME 8

ii March 2009

Foreword

The first edition of the Manual was published in 1960 and was actually based on the experiences and knowledge of DID engineers in planning, design, construction, operations and maintenance of large volume water management systems for irrigation, drainage, floods and river conservancy. The manual became invaluable references for both practising as well as officers newly posted to an unfamiliar engineering environment. Over these years the role and experience of the DID has expanded beyond an agriculture-based environment to cover urbanisation needs but the principle role of being the country’s leading expert in large volume water management remains. The challenges are also wider covering issues of environment and its sustainability. Recognising this, the Department decided that it is timely for the DID Manual be reviewed and updated. Continuing the spirit of our predecessors, this Manual is not only about the fundamentals of related engineering knowledge but also based on the concept of sharing experience and knowledge of practising engineers. This new version now includes the latest standards and practices, technologies, best engineering practices that are applicable and useful for the country. This Manual consists of eleven separate volumes covering Flood Management; River Management; Coastal Management; Hydrology and Water Resources; Irrigation and Agricultural Drainage; Geotechnical, Site Investigation and Engineering Survey; Engineering Modelling; Mechanical and Electrical Services; Dam Safety, Inspections and Monitoring; Contract Administration; and Construction Management. Within each Volume is a wide range of related topics including topics on future concerns that should put on record our care for the future generations. This DID Manual is developed through contributions from nearly 200 professionals from the Government as well as private sectors who are very experienced and experts in their respective fields. It has not been an easy exercise and the success in publishing this is the results of hard work and tenacity of all those involved. The Manual has been written to serve as a source of information and to provide guidance and reference pertaining to the latest information, knowledge and best practices for DID engineers and personnel. The Manual would enable new DID engineers and personnel to have a jump-start in carrying out their duties. This is one of the many initiatives undertaken by DID to improve its delivery system and to achieve the mission of the Department in providing an efficient and effective service. This Manual will also be useful reference for non-DID Engineers, other non-engineering professionals, Contractors, Consultants, the Academia, Developers and students involved and interested in water-related development and management. Just as it was before, this DID Manual is, in a way, a record of the history of engineering knowledge and development in the water and water resources engineering applications in Malaysia. There are just too many to name and congratulate individually, all those involved in preparing this Manual. Most of them are my fellow professionals and well-respected within the profession. I wish to record my sincere thanks and appreciation to all of them and I am confident that their contributions will be truly appreciated by the readers for many years to come.

Dato’ Ir. Hj. Ahmad Husaini bin Sulaiman, Director General, Department of Irrigation and Drainage Malaysia

DID MANUAL VOLUME 8

March 2009 iii

Acknowledgements

Steering Committee:

Dato’ Ir. Hj. Ahmad Husaini bin Sulaiman, Dato’ Nordin bin Hamdan, Dato’ Ir. K. J. Abraham, Dato’ Ong Siew Heng, Dato’ Ir. Lim Chow Hock, Ir. Lee Loke Chong, Tuan Hj. Abu Bakar bin Mohd Yusof, Ir. Zainor Rahim bin Ibrahim, En. Leong Tak Meng, En. Ziauddin bin Abdul Latiff, Pn. Hjh. Wardiah bte Abd. Muttalib, En. Wahid Anuar bin Ahmad, Tn. Hj. Zulkefli bin Hassan, Ir. Dr. Hj. Mohd. Nor bin Hj. Mohd. Desa, En. Low Koon Seng, En. Wan Marhafidz Shah bin Wan Mohd. Omar, Sr. Md Fauzi bin Md Rejab, En. Khairuddin bin Mat Yunus, Cik Khairiah bt Ahmad. Coordination Committee: Dato’ Nordin bin Hamdan, Dato’ Ir. Hj. Ahmad Fuad bin Embi, Dato’ Ong Siew Heng, Ir. Lee Loke Chong, Tuan Hj. Abu Bakar bin Mohd Yusof, Ir. Zainor Rahim bin Ibrahim, Ir. Cho Weng Keong, En. Leong Tak Meng, Dr. Mohamed Roseli Zainal Abidin, En. Zainal Akamar bin Harun, Pn. Norazia Ibrahim, Ir. Mohd. Zaki, En. Sazali Osman, Pn. Rosnelawati Hj. Ismail, En. Ng Kim Hoy, Ir. Lim See Tian, Sr. Mohd. Fauzi bin Rejab, Ir. Hj. Daud Mohd Lep, Tn. Hj. Muhamad Khosim Ikhsan, En. Roslan Ahmad, En. Tan Teow Soon, Tn. Hj. Ahmad Darus, En. Adnan Othman, Ir. Hapida Ghazali, En. Sukemi Hj. Sidek, Pn. Hjh. Fadzilah Abdul Samad, Pn. Hjh. Salmah Mohd. Som, Ir. Sahak Che Abdullah, Pn. Sofiah Mat, En. Mohd. Shafawi Alwi, En. Ooi Soon Lee, En. Muhammad Khairudin Khalil, Tn. Hj. Azmi Md Jafri, Ir. Nor Hisham Ghazali, En. Gunasegaran M., En. Rajaselvam G., Cik Nur Hareza Redzuan, Ir. Chia Chong Wing, Pn Norlida Mohd. Dom, , Ir. Lee Bea Leang, Dr. Md. Nasir Md. Noh, Pn Paridah Anum Tahir, Pn. Nurazlina Mohd. Zaid, PWM Associates Sdn. Bhd., Institut Penyelidikan Hidraulik Kebangsaan Malaysia (NAHRIM), RPM Engineers Sdn. Bhd., J.U.B.M. Sdn. Bhd. Working Group: Pn. Hjh. Wardiah bte Abd. Muttalib, Tn. Hj. Md Yusof bin Ibrahim, Ir. Hj. Kamaluddin bin. Othman, Tn. Hj. Muhd Khosim bin. Ikhsan, En. Ayasing bin. Long, Cik Dayang Esmayati Abu Seman, Pn. Hasnizan bte. Hashim, En. Muhammad Suhaimi bin. Md Ali, Mr. Rajaselvam a/l Govindaraju, En. Zulkefli bin. Mat Sain, Ir. Hapida bte. Ghazali, En. Mohd Faizul bin Mustapha, En. Baharudin bin Ibrahim, En. Shazenas bin. Jamaluddin, En. Zafri bin. Mamat, Tn. Hj. Ismail Bin Ahmad, Ir. Yap Cheng Aun, Ir. Kiang Keng Hong, Ir. Fong Chin On, Ir. Lim Lee Thon, Ir. Pang Teck Sin, Ir. Yahya Md Yatim, Ir. Mahmood bin Hj Taib, Ir. Mobarak bin Hussein , Ir. Loh Bak Kim, Mr. John Lai, En. Ahmad Ashrin Abdul Jalil.

DID MANUAL VOLUME 8

iv March 2009

Registration of Amendments

Amend

No

Page No

Date of Amendment

Amend No

Page No

Date of Amendment

DID MANUAL VOLUME 8

March 2009 v

Table of Contents

Disclaimer .................................................................................................................................. i

Foreword .................................................................................................................................. ii

Acknowledgements ....................................................................................................................iii

Registration of Amendments ...................................................................................................... iv

Table of Contents ...................................................................................................................... v

List of Volumes ........................................................................................................................ vi

List of Abbreviations ................................................................................................................. vii

Chapter 1 Pumping Installation Chapter 2 Gate Design Chapter 3 Ground Water Facilities

Chapter 4 Safety and Health

Chapter 5 Plant Management and Control

Chapter 6 Energy Efficiency in Management Of M&E Installation

Chapter 7 Electrical Service Chapter 8 Dredger Chapter 9 Asset Management Chapter 10 Introduction to SCADA and Automation System

DID MANUAL VOLUME 8

vi March 2009

List of Volumes

Volume 1 FLOOD MANAGEMENT Volume 2 RIVER MANAGEMENT Volume 3 COASTAL MANAGEMENT Volume 4 HYDROLOGY AND WATER RESOURCES Volume 5 IRRIGATION AND AGRICULTURAL DRAINAGE Volume 6 GEOTECHNICAL MANUAL, SITE INVESTIGATION AND ENGINEERING SURVEY Volume 7 ENGINEERING MODELLING Volume 8 MECHANICAL AND ELECTRICAL SERVICES Volume 9 DAM SAFETY, INSPECTIONS AND MONITORING Volume 10 CONTRACT ADMINISTRATION Volume 11 CONSTRUCTION MANAGEMENT

DID MANUAL VOLUME 8

March 2009 vii

List of Abbreviations

ANS American National Standard

ASTM American Standard for Testing Of Materials

AWWA American Water Works Association

BS British Standard

CCTV Closed Circuit Television

CSD Cutter Suction Dredge

DB Distribution Board

DFB Distribution Fuse Board

DID Department of Drainage and Irrigation

E/F Earth fault

GPRS General Package Radio Service

GSM Global System for Mobile Communication Network

HDPE Polyethylene

ICT Information and Communication Technology

IDMT Inverse Definite Minimum Time

IEE Institution of Electrical Engineers

ISO International Standard Organisation

JIS Japanese Industrial Standard

JKKP Jabatan Keselamatan & Kesihatan Pekerjaan

LV Low Voltage

MSB Main Switchboard

NEMA National Electric Manufacturers Association (USA)

NPSH Nett Positive Suction Head

O/C Over current

OSHA Occupational Safety and Health Act

PABX Private Automatic branch Exchange

PLC Programmable Logic Controller

PPE Personal protective Equipment

PVC/SWA/PVC Polyvinyl chloride/Steel wire armoured/polyvinyl chloride

SCADA Supervisory Control And Data Acquisition

SMS Short Message Service

S.O. Superintending Officer

s/o/o Switch Socket Outlet

TCG Tidal Control Gate

DID MANUAL VOLUME 8

viii March 2009

TNB Tenaga Nasional Berhad

TSHD Trailing Suction Hopper Dredge

USBR United States Bureau Of Reclamation

CHAPTER 1 PUMPING INSTALLATION

Chapter 1 PUMPING INSTALLATION

March 2009 1-i

Table of Contents

Table of Contents .................................................................................................................... 1-i

List of Tables ..................................................................................................................... 1-ii

List of Figures……………………………………………………………………………………………………………..……….1-iii

1.1 TYPE OF PUMPS USED IN DID ...................................................................................... 1-1

1.2 PUMP PERFORMANCE AND CHARACTERISTICS .............................................................. 1-6

1.3 SYSTEM CHARACTERISTICS ......................................................................................... 1-8

1.4 PUMPING ARRANGEMENTS .......................................................................................... 1-8

1.5 PUMP AUTOMATIC CONTROL ....................................................................................... 1-8

1.6 PUMP NUMBERS DETERMINATION ................................................................................ 1-9

1.7 PIPEWORK CALCULATION .......................................................................................... 1-10

1.8 PUMP SELECTION ...................................................................................................... 1-11

1.9 PIPING, VALVES, JOINTS & SUPPORTS ....................................................................... 1-13

1.10 PUMP SUMP DESIGN AND DIMENSIONS ...................................................................... 1-13

1.11 DISCHARGE BASIN / OUTLET (DISCHARGE) STRUCTURE ............................................. 1-18

1.12 BASIC LAYOUT PLANNING FOR A PUMPING STATION .................................................. 1-19

1.13 AUXILIARY EQUIPMENT ............................................................................................. 1-21

1.14 INSTALLATION WORKS .............................................................................................. 1-26

1.15 TESTING AND COMMISSIONING OF PUMPING SYSTEM ................................................ 1-25

1.16 PUMP TESTING ......................................................................................................... 1-27

1.17 PUMPING STATION MODEL TEST................................................................................ 1-27

1.18 OPERATION & MAINTENANCE OF THE PUMPING INSTALLATION .................................. 1-29

APPENDIX 1A ALIGNMENT CHART FOR FLOW IN PIPES. HAZEN-WILLIAMS FORMULA ............ 1A-1

APPENDIX 1B GENERAL GUIDELINES ON PUMP WITNESS TESTS........................................... 1A-2


1-ii March 2009

List of Tables

Table Description Page

1.1

1.2

1.3

1.4

1.5

Pump Characteristics For Various Types Of Pump

Motor Housepower Vs Number of Pumps Installed

Minimum Sump Lengths

Typical Features of Various Automatic Mechanized Raking Equipments

Permissible Tolerance

1-6

1-10

1-18

1-22

1-27

List of Figures Figure

Description Page

1.1(a) End Suction Pump 1-1

1.1(b)

1.1(c)

1.1(d)

1.1(e)

1.1(f)

1.2(a)

1.2(b)

1.3(a)

1.3(b)

1.4

1.5

1.6

1.7

1.8(a)

1.8(b)

1.9(a)

1.9(b)

1.10(a)

1.10(b)

1.11

Archimedean Screw Pumps

Propeller Pump

Mixed Flow Pump

Electrical Submersible Pump

Electrical Submersible Propeller Pump

Permanent Wet Pit Installation

Dry Pit Installation

General View of Portable Hydraulic Pumpset(Back View)

General View of Portable Hydraulic Pumpset(Front View)

Variation in Impeller Profile with Specific Speeds & Pump Characteristic Curves

Pump performance characteristic

Pump / Motor Monitoring Unit

Pump Selection Flow Chart

Typical Examples of Suction Pumps

Typical Examples of Suction Pumps

Single Pump Sump

Multiple Pump Sump

Discharge Chamber Arrangement (1)

Discharge Chamber Arrangement (2)

Typical Pumping Station General Layout

1-1

1-2

1-2

1-3

1-3

1-3

1-4

1-5

1-5

1-7

1-8

1-9

1-12

1-15

1-16

1-17

1-19

1-19

1-20

1-21


March 2009 1-iii

Figure

1.12

1.13

1.14

Description

Stationary Screen General Layout

Crane General Arrangement

Stoplog General Arrangement and Construction

Page

1-23

1-24

1-25


1-iv March 2009

(This page is intentionally left blank)


March 2009 1-1

1 PUMPING INSTALLATION

1.1 TYPE OF PUMPS USED IN DID Generally, most of the pumps used in DID are high volume - low head type. Mixed-flow and axial-flow are most commonly used for both irrigation pumping and flood control. Paddy field irrigation pump operates continuously during the planting season while flood drainage pump operates intermittently whenever the inflow water is excessive and during flood. However for high heads, radial-flow and/or Francis type may be used particularly in long delivery pipeline system. Lately, Archimedean screw pumps have also been installed in view of its capability in handling large volume of water over a wide range of flow rates without clogging. However, civil works is expected to be expensive as it takes up substantial floor space on installation. Pumps of various design configurations are as shown in Figures 1.1 (a) (b) (c) (d) (e) & (f).

Fig. 1.1(a) End Suction Pump

Fig. 1.1(b) Archimedean Screw Pumps


1-2 March 2009

Axial flow design for highest capacity requirements

Fig. 1.1(c) Propeller Pump

Mixed flow unit with diffuser and closed impeller for higher head applications

Fig. 1.1(d) Mixed Flow Pump


March 2009 1-3

Fig. 1.1(e) Electrical Submersible Pump

Fig. 1.1(f) Electrical Submersible Propeller Pump

Conventionally, pumping stations with massive superstructure have been built to house the long-shaft driven pumps submerged in water and with the prime mower at floor level. Hitherto, more compact and integral electrical submersible pump-sets have gained popularity over the conventional long-shaft-driven pumps in view of its simplicity in installation work and it needs minimal superstructure. Construction of the pumping station can either be wet pit or dry pit, but wet-pit installation is commonly adopted. Typical arrangement of the wet-pit and dry-pit installation pumping station is as shown in Fig. 1.2 (a) & (b).

Fig 1.2(a) Permanent Wet Pit Installation


1-4 March 2009

Fig 1.2(b) Dry Pit Installation Basically all pumping stations are operated manually, and most of the recently built large installations particularly flood control have been improved with automatic control system. Attempts have been made to incorporate the state-of-the-art technology in control and monitoring to the newly built pumping stations for remote monitoring and control. (a) Portable Pump Sets Besides the fixed pumping stations, portable pump-sets are commonly deployed for emergency use. They are mobilized either to supplement water for irrigation or to dewater in flooded area. Hydraulic submersible pump-sets are commonly used as they are easy to handle, operate and install, and require minimum civil work in installation. Normally they are skid-mounted as shown in Figures 1.3 (a) & (b). As an alternative, portable electrical pump-sets complete with independent canopy-type generating set have been included for its quietness in operation. However, a competent person should be assigned in operating the generating-set.


March 2009 1-5

Water Pump Coupled with Hydraulic Motor

Fig 1.3(a) General View of Portable Hydraulic Pumpset (Back View)

Hydraulic Power Pack

Fig 1.3(b) General View of Portable Hydraulic Pumpset (Front View)

(b) Dredge Pumps In dredging works, dredged materials are normally conveyed to the dumping ground through the long discharge pipeline by means of the solid handling pumps such as dredge pump, sand and gravel pump etc. They are subjected to high wearing rate due to the abrasiveness of the solid material being handled, they are either rubber-lined or double-walled, or constructed with wear resistant material such as Ni-Hard (Martensitic white irons). They are made very rugged and simple with large clearances. Pump design is of volute, single stage, single-suction type and has a closed single curvature, non-clogging, overhung, radial curved-vane runner. Stuffing box, which provides a seal around the runner shaft when it enters the pump casing, is flushed with clear water continually in preventing sand from getting into it.


1-6 March 2009

1.2 PUMP PERFORMANCE AND CHARACTERISTICS Pump overall performance is always expressed by characteristic curves of the total head, horsepower and efficiency plotted against capacity at constant speed. Fig 1.4 shows the typical pump characteristics of various types of pumps with respect to the pump specific speed (Ns). Table below shows types of pumps for various specific speeds.

Table 1.1 Pump Characteristics for Various Types Of Pump

Pump Type Radial / Francis Mixed-flow Axial- flow

Specific speed range (Ns) – metric unit

Radial : 10 – 60 Francis: 30 - 90

90 - 160

> 160

Head (m) High head,

18 – 300 Moderate head, 9 - 18

Low head, 3 – 9

H – Q curve Flat Moderate steep Steep Efficiency High High High Power curve: (i) Unstable and overloading (ii) Stable and non-overloading

Yes at lower Ns. Yes, at higher Ns.

-

Yes, power curve varies little with working range.

-

Yes, power curve falls rapidly with flow.

Suction lift High Moderate Low General Heavy and higher

equipment cost Moderate Smaller and

cheaper


March 2009 1-7

Fig. 1.4 Variation in impeller profile with specific speeds and pump characteristic curves

Impellers of different types usually have widely different performance characteristics, as indicated by the shapes of the characteristic curves for capacity, head, power and efficiency. Pumps of low specific speed will have a relatively flat curve capacity while high specific speed pumps will exhibit a steeper curve. Flat curve pumps experience a large change in capacity with a moderate change in total head, whereas a steeper head-capacity (H-Q) curve pumps have the advantage that a major change in total head result in a small variation in capacity/flow rate.


1-8 March 2009

A steep H-Q curve may be preferred for pumping water from the river where fluctuation of river water level is prevalent, thus constant pump discharge is expected. 1.3 SYSTEM CHARACTERISTICS Pump is normally designed with its best efficiency at the intersection of the pump head-discharge curve and the system head curve. The system head curve can be represented graphically by combining the static head and system friction head as shown below.

Fig. 1.5 Pump performance characteristic

1.4 PUMPING ARRANGEMENTS It is a common practice to have a multiple-pumps pumping system to cater for the duty required. Pumps may be arranged to operate independently with individual delivery system or to operate in parallel in a single delivery pipeline. However, when operated in parallel, because of the additional resistance incurred it is unlikely to achieve the theoretical increase in flow rate. Where large quantities of discharge are required at high heads, multiple pumps in series may be used. However, such system is rarely common in DID application. 1.5 PUMP AUTOMATIC CONTROL Hitherto, most of the pumping stations are provided with automatic control system with manual override. A control based on water level in the pump sump or in the discharge canal is commonly used as a control constant for irrigation and drainage applications. The automatic level-responsive pump control is designed for (a) pump-up mode in filling up the canal to the designed full supply level for irrigation purpose or (b) pump-down mode in keeping the sump water level under a certain level for flood control. For reliable automatic control, especially in land drainage pumping station, due consideration shall be given to the consequences of the failure of any station components in the design stage. All practical provisions should be made for continual station operation under such component failure conditions. Critical components may be provided in duplicate as standby and additional pumping unit shall be provided. For larger pumping stations, standby generating-set may be provided as an alternative source of power supply in the event of power outage.


March 2009 1-9

Monitoring system is to be built-in to ensure reliable, safe and efficient pump operation. Monitoring features shall include (i) status indication of plant operating conditions (ii) alarm monitoring of plant parameters for malfunctioning and out-of-limit conditions and (iii) automatic protective shutdown devices for faulty operating conditions and set-limit conditions. Typical pump/motor monitoring unit is as shown in Fig. 1.6.

Fig. 1.6 Pump / Motor Monitoring Unit

In multiplex pump stations, features such as pump cycling and sequencing timing are incorporated. Pumps are operated to meet the varying inflow / outflow demands of the system. Alternating pump starting will help in equalizing pump wear and minimizing the starting frequency of each particular pump. 1.6 PUMP NUMBERS DETERMINATION In determining the number of pumps to be used, it is necessary to consider the following factors: - a) Pumping capacity required for the proposed scheme; b) Equipment cost and operating cost; c) Operational control system; d) Reliability and critical situation, and e) Civil construction cost.

To maintain the flexibility in operation and to adopt the demand variation, preferably sufficient number of same capacity pumping unit should be provided. Considering reserve capacity of the pumping installation, sometimes an additional same capacity unit may be installed as standby to cater for emergency use particularly for storm water pumping installations. Generally 3 to 4 duty pumpsets are preferred. If two (2) pumpsets are installed, each pump should be sized to pump not less than 2/3 of the total capacity required. In flood control application, one (1) smaller capacity pumping unit is normally provided to cater for low flow condition while the larger duty pumps dealing with all flood/storm water. However, in automatic control stations the number of pumps may be governed by the available depth between the highest cut-in and lowest cut-out levels.


1-10 March 2009

In a smaller scale pumping station, there shall be one duty pump capable of dealing with the maximum flow or maximum demand to be accommodated plus a standby unit. In determining the number of pumps required, due consideration shall be given to the maximum motor horsepower of the motor being used, particularly in large pumping installation. For normal LV application, the TNB substation loading capacity is limited to about 1000 amperes. As such, maximum motor horsepower of the motor being used becomes the limiting factor in determining the number of pumps required as follows: -

Table 1.2 Motor Housepower Vs Number of Pumps Installed

Maximum motor horsepower (kW)

Full load current (Amps)

No. of pumps used (For single chamber substation)

110 130 160 220

180 213 262 360

5 4 3 2

1.7 PIPEWORK CALCULATION a) System Hydraulics The head required by the system is the sum of the static head (difference in elevation) plus the variable head (friction and turbulence in the pipe, bends, fittings etc.) i.e. Total dynamic head = Static discharge head + Static suction lift + System friction loss OR Total dynamic head = Static discharge head - Static suction head + System friction loss Based on the Darcy Weisbach equation, Hazen and Williams method as shown in is commonly used for waterworks and irrigation applications in computing the friction loss on straight pipes as follows: - Hf = 10.666 x (1.1)

Where Hf = Friction losses in the pipeline (m)

L x Q 1.85 D 4.87 x C 1.85

Q = Rate of flow through pipe (m / sec) C = Hazen and Williams factor (refer to Appendix 1.1) (C =130 fornew steel pipe, C=100 for old pipe) D = Pipe internal diameter (m) L = Total length of pipeline (m)

Friction losses in valves and fittings and other appurtenances can be expressed as follows: -

ΔH = ζ x V2 / 2g (1.2) Where ΔH = Friction losses in valves, fittings etc ζ = Loss coefficient V = Average velocity (m / s) g = Acceleration of free fall (9.8 m / sec2)


March 2009 1-11

b) Pipe Sizing In normal practice, pipe sizing is based on the continuity equation viz.

Q = VA (1.3)

where Q = flow rate V = flow velocity A = cross section area of flow

The flow velocity in the suction line should preferably be limited to 2 m/s, while the flow velocity in the delivery line should not exceed 3 m/s. In general, low velocities should be used on the suction side of the pump to keep frictional losses as low as possible and improve the NPSH. On the delivery side the fluid is under pressure and higher flow velocities can be used without trouble. Where pipelines are short and the head is mostly static head, pipe sizing is generally considered on the basis of flow rate. However, for high friction system (i.e. long delivery pipeline) due consideration shall be given on the cost of pipework. Excessive friction will result from too small a pipe (flow velocity too high) and excessive cost incurred resulting from the use of unnecessarily large pipe (flow velocity too low). The effect of flow velocity should be investigated so as to arrive at the economic pipe size. 1.8 PUMP SELECTION Besides pump capacity and number units of pumps, various factors such as operating frequency and station reliability shall be looked into in the selection of pumps. Where service is more important than the cost and/or the operation is intermittent, a low efficiency pump would be quite suitable taking into consideration of saving in the equipment cost. But where pumps are subjected for long hours continuous running, then the pump type would be selected on the basis of highest efficiency at the required capacity and head. Capital cost, running cost and maintenance cost should also be taken into consideration. Generally small fast-running pumps are lower in initial cost than large slow-running pumps. High specific speed pumps are comparatively low in equipment cost, but require deep submergence which would lead to increased plant construction cost. Construction and material of the pumps selected must satisfy the function of the pumping station particularly materials must be suitable for the medium being handled. The initial cost of the pump is greatly affected by the material selected. Appropriate selection of material might result saving in maintenance costs and cost of downtimes. Running costs are directly related to the power and efficiency of the pumps and prime mower, thus pump having highest possible efficiency and driver of low running cost are preferred. Maintenance cost includes repair cost, replacement parts cost and downtime cost etc. Pumps of good quality and good back-up service might help in saving maintenance cost. Generally economic life of an electrical pumpset is about 25 years and 15 years for diesel-driven pumpset. Pumps shall be selected to operate at their best efficiency point (BEP) at the designed pump capacity, and ideally the system operating point coincides with the pump BEP. Average system operating conditions rather than the maximum conditions shall be adapted for the best pump selection, and the pump must be able to deliver reasonable flow in worse conditions. Besides, the net positive suction head (NPSH) available in the pumping system must be better than the NPSH required for the pump. In sizing the pump, the rated power of the motor should be about 10% higher than that of the power requirement of the pump. Where variable speed drive is incorporated, power reserve of about 15% must be taken into consideration.


1-12 March 2009

As a guide, a step-by-step procedure for the selection of pumps is depicted as shown in flow chart Fig. 1.7 attached.

(Qa, Ha & Na) No No No If Hb ≠ Ha Hb ≈ Ha

Preliminary pump selection completed

Estimate total head Preliminary plant layout

Motor speed (rpm) 1500, 1000, 750,

500

Assign pump speed (Na)

Determine type of pump

Obtain manufacturer’s pump performance curves, select appropriate pump needed and

impeller size

Evaluate pump performance and assess its suitability

Plot pump and system H-Q curve, determine efficiency, power and NPSH

required

Is the efficiency satisfactory?

Check condition NPSH available > NPSH

Reassess total head

Determine no. of pumping units required and pump capacity (Qa)

Scheme Pumping

Figure 1.7 Pump Selection Flow Chart


March 2009 1-13

1.9 PIPING, VALVES, JOINTS & SUPPORTS Normally steel pipes are commonly used for discharge piping system where the medium being handled is not acidic or corrosive. Ductile iron pipes would be used when handling acidic liquid because of its high corrosive resistible characteristics. When steel pipes are used, they are either galvanized or coated with coal tar enamel. Sometimes, high-density polyethylene (HDPE) pipes are used in place of steel pipes because of its excellent chemical and corrosion resistant properties. They are much lighter per meter length, tough and durable. Because of the exceptional smooth inner surface, friction loss in water flow is minimized. Determination of pipe wall thickness shall be based on the tensile stresses due to internal pressure and stresses produced by the bending of the pipe due to external pressure when buried underground. Where long pipeline is installed, due consideration shall be given to impact pressure due to water hammer. An allowance of 1 ~ 2mm thickness is allowed for against corrosion. Pipes should be adequately supported. Supports should be provided near changes in direction, elbows, branch lines and near valves. Valves and other heavy piping components should be individually supported. Long vertical pipes should be fixed not only at the lowest part but also at the intermediate locations with center rest fittings to aloe for expansion. Pipes laid on slope shall be fixed in such a manner that sliding in the axial direction is prevented. Concrete thrust blocks must be provided to resist the force or combination of forces which tends to produce joint separation. A pipe to which a flexible / expansion joint is installed should be supported properly at locations close to the joint. Buried pipes should be properly supported and aligned to avoid settlement. Cover to buried pipes shall not be less than 900mm from ground surface. The cover shall be increased to 1200mm from ground surface underneath roadway unless specially protected. Valves commonly used in DID pumping applications can be classified into three categories as follows:- a) valves for flow control b) valves for stopping water flow c) valves for reverse flow prevention and d) valves for surge control. Gate valves are commonly used in both shutting off and flow control. Where frequent opening and closing operation is not required, non-rising stem type is preferred. To prevent back flow of water upon pump stop, flap valves are installed at the end of the discharge pipe or alternatively swing check valves are provided close to the pump discharge end. Where water hammer effect is expected, special type of fast-closing check valves or pump control valves might be useful in controlling surges. 1.10 PUMP SUMP DESIGN AND DIMENSIONS To ensure reliable and efficient pump performance, it is essential that the hydraulic design of the intake structure produce satisfactory flow conditions at the inlet to the pump. Pump sump design covers (a) submergence, (b) floor clearances, (c) sump design and (d) sump intake or flow distribution in the sump.


1-14 March 2009

Some simple guidelines for sump design are as follows: - Design the sump for a flow velocity in the sump channels of about 0.3 m/sec at the lowest

sump water level. - Avoid sudden changes in the direction of flow. - Abrupt changes in sump floor elevations should not be permitted within about five bell

mouth diameters from the side of the pump. - The flow should be parallel to the sump walls. The design of the pump sump is important particularly for large axial-flow and mixed-flow pumps. The suction side of the pump affects pump performance adversely, poor flow condition in the suction well or poor entrance conditions about the pump-suction well will cause poor performance and vibration, vortex formations, overloading of the driver etc. Generally the flow of water into any pump should be uniform, steady, without swirl and without entrained air. Typical examples of undesirable suction sump configuration and their improvements are as shown in Fig. 1.8 (a) & (b). Any deviation from the basic design rules requires that sump model tests be performed. Whenever new design departs significantly from established configurations, model tests of the pump sump and its approaches should be conducted.


March 2009 1-15

Fig. 1.8(a) Typical examples of suction pumps


1-16 March 2009

Fig. 1.8(b) Typical examples of suction pump Established institutions provide guidelines in the design of pump sump and pump sump dimensions i.e. American Hydraulic Institute, and the British Hydromechanics Research Association. However, the pump sump dimensions shall be verified based on pumps manufacturer’s recommendations. Typical examples on the pump sump dimensions are as shown in Fig. 1.9 (a) & (b). Should the new design deviates from the basic sump configurations model tests of the pump sump and its approaches should be performed.


March 2009 1-17

a) Wet well pump sumps

b) Dry well arrangements i) Horizontal Intake ii) Turned-down bellmouth

c) Length of approach channel

Fig 1.9(a) Single Pump Sumps


1-18 March 2009

Table 1.3 Minimum Sump Lengths

a/A L/D Comments 1 4 Full width band screen no obstructions

0.8 6 - 0.5 10 -

Less than 0.5 - Baffles needed

(a) Open Sump

(b) Unitised Sump


March 2009 1-19

c) Approach Channel Sump

Fig 1.9(b) Multiple Pump Sumps

1.11 DISCHARGE BASIN / OUTLET (DISCHARGE) STRUCTURE The outlet structure is intended to convert the water energy into the potential energy at the water is finally released into the open air. The flow velocity should be held in between 0.3 to 0.5 m/s. To prevent overflow, height of the structure should be always above the highest water level at the full supply level or at the total maximum pump discharge. A typical dimension of outlet structure is as shown in Fig. 1.10.

Fig 1.10(a) Discharge Chamber Arrangement (1)


1-20 March 2009

Fig 1.10(b) Discharge Chamber Arrangement (2)

1.12 BASIC LAYOUT PLANNING FOR A PUMPING STATION Generally the overall layout planning should cover the following items: - - Approach channels, pump sump & discharge tank – size and configuration; - Pumping station layout – arrangement, functionality and space requirements; - Basic pump layouts – arrangement, space requirements; - Auxiliary equipment layout – arrangement, space requirements; - Electric room & field control room layout – arrangement and space requirements; - Other facilities – safety, security, Acts and statutory requirements.

General considerations in the layout planning are as follows: - - Positioning, configuration, space requirements, and aesthetics. - Safety, security, accessibility, functionality - Ease of installation, operation and maintenance, control

Typical general layout of the pumping station is as shown in Fig 1.11


March 2009 1-21

Fig 1.11 Typical Pumping Station General Layout


1-22 March 2009

1.13 AUXILIARY EQUIPMENT a) Trash Racks & Stationary Screens To prevent damage to the impellers of the pump and to avoid blockage to the pump’s suction opening, a pumping station should be equipped with a trash rack. Trash rack is classified into such types as movable (mechanised) and fixed (stationary). It is a common practice to install hand cleaned stationary screens to small scale pumping installation where trash volume is low, channel depth is not deep and labour force is readily available. However, automatic mechanized trash racks are more suited to large scale pumping installation where quantities of trash to be raked are substantial and continuous raking operations are to be performed. Off the shelf automatic operated machines of various design and construction are readily available. They are divided into three main types: (i) chain-operated type; (ii) cable-driven; and (iii) articulated arm type with hydraulic cylinder. Comparison of the various types of mechanized raking equipment is as shown below: -

Table 1.4 Typical Features of Various Automatic Mechanized Raking Equipment

Item Chain-operated Cable-operated Articulated arm type hydraulically-operated

Trash size Bulky and large sized objects

Limited by the rake size

Capable to handle heavy and large sized objects.

Raking capacity

Good trash handling capacity because of its continuous raking-up operation

Limited trash handling capacity because of its reciprocating action

Trash handling capacity is affected due to reciprocating action, unless wider raking attachment is used.

Maintenance Submerged sprockets, requiring frequent attention and difficult to maintain. Frequent adjustment and repair of chains.

Does not have submerged parts, rake is the only mechanical parts entering the water. Maintenance problem related to slack cables, fouled cable reels and improperly operating brake mechanism.

All parts requiring maintenance is above water and can be easily inspected and maintained. Hydraulic system requires special attention.

Depending on the nature, size and quantity of trash to be raked, it is essential that in the selection of the correct type of equipment to be installed, due consideration shall be taken in the area of application, installation, operation and maintenance of the equipment. Clear opening between bars shall match the size and type of pump being installed. The velocity through the bars should not exceed 0.9 m/s while the headloss through the bar racks is limited to 150 mm by operational controls. Centralised trash collection facilities such as the conveyor belt system may be incorporated where multiple bays are to be cleaned. Operation control of the mechanized trash rack should be preferably a combination of time clock and differential water level control. The timing device provides an intermittent and regular intermittent automatic operation while the auxiliary differential level control will set the cleaning mechanism in operation automatically at predetermined value. The auxiliary control operates independently of the regular control.


March 2009 1-23

General layout and dimensional requirement of the stationary screen is as shown in Fig. 1.12.

Information required: - Channel width (W) Channel depth (H) Angle of inclination (θ) Highest water level (HWL) Lowest water level (LWL) Clear spacing between bars (S)

Fig 1.12 Stationary Screen General Layout

b) Overhead Crane Stationary crane of monorail type is more commonly used in small scale pumping installation where lifting load is relatively light and usage is infrequent. Hand chain hoist and electric hoist equipped with geared trolley lend itself to such application. Electric overhead traveling crane is well suited to moderate size and large size pumping stations for the load to be handled. For outdoor application, gantry crane may be suited for unusual site conditions and special application. Design of the crane structure shall be based on the type of service required. Hoist unit shall be seized to lift the heaviest individual component in the station. It shall be hung at sufficient height to give ample space above the floor level to allow for the working depth of the hoist, and the crane hook should be capable of reaching the machinery to be hoisted at its installed position. Prior to the installation of the electric crane, compliance to the Jabatan Keselamatan & Kesihatan Pekerjaan (JKKP) requirement is warranted such as application for registration (JKJ 105). Documents such as (i) letter of confirmation from Consultant on crane runway structure (to be chopped and signed by civil Professional Engineer), (ii) crane design calculation and (iii) crane test certificate from Manufacturer. Electric overhead crane is subjected to load test to the regulations and requirements of Jabatan Keselamatan & Kesihatan Pekerjaan (JKKP). The test will be witnessed and certified by JKKP prior to the issuance of Certificate of fitness. JKKP. As stipulated in the Act, the hoisting machinery is subjected to inspection at regular interval. General layout and dimensional requirement of the crane is as shown in Fig. 1.13.


1-24 March 2009

Fig. 1.13 Crane General Arrangement

c) Stoplog Stoplog grooves are provided ahead of the trash racks for purpose of maintenance and repair work. Stainless steel side seal plates or mild steel guides are fixed to the grooves so that the stoplog elements are properly guided into the slots. Normally stoplog is made up of three (3) to five (5) pieces of mild steel panels to the required height to block out the water from entering the approach channel. Decision of the number of elements is governed by the admissible space available and the limitation of the lifting effort. Each panel shall be limited to less than 2000 kg so that it can be easily handled with a light duty lifting device or lorry-mounted crane. Side rollers are provided to facilitate easy insertion of the element. The stoplog is normally designed for balanced condition, but main rollers may be required if unbalanced condition prevails. Effective sealing is accomplished with the combination of seal seals and bottom seal to each element. Design of the lifting device shall be capable of being self-engaged and released easily to the lifting bracket of the stoplog element. General arrangement, construction and dimensional requirement of the stoplog elements are as shown in Fig. 1.14.


March 2009 1-25

Fig 1.14 Stoplog General Arrangement & Construction


1-26 March 2009

d) Generating Set For reliable operation, sometimes generating set is installed to provide back-up electrical power supply in the event of TNB outage. Depending on the severity of the consequences, generating set is provided mainly for flood mitigation project. Compliance to Jabatan Alam Sekitar requirement is warranted for the installation of the generating set. Chargeman of the appropriate grade should be assigned to look after the gen-set operation. 1.14 INSTALLATION WORKS Installation works needs to be treated with care as equipment damage, malfunction and operating problems would result if it were not properly installed. Ensure that method statement, which details how the work is to be done, is readily available and is being adhered accordingly. Assign skilled and trained craftsman, equip with adequate and proper tools and equipment, and maintain good current engineering practices in the execution of the work. Ensure that safety precautions are being implemented and safety rules are being closely observed. 1.15 TESTING AND COMMISSIONING OF PUMPING SYSTEM Plants and equipment are subject to testing and commissioning before being turned over to the user. The purpose of the testing and commissioning is to make sure that all equipment and systems not only are functional and operational but also meet the performance requirements. Testing should be properly planned and executed in order to avoid unnecessary delay at site. All parties involved shall be closely coordinated, and systematic approach to the testing shall be adapted with clear written instructions and test records. Pre-start Checks To begin with, inspect the equipment in accordance with the manufacturer’s submittals to confirm correct equipment is installed. The inspection team comprising all the related parties shall verify the proper installation, and supervise any adjustments and installation checks. Having satisfied with the equipment installation status, an official report shall be accompanied certifying that the equipment is properly installed and is ready to operate. Electrical Systems – Energizing Upon completion of the pre-start checks above, conduct a thorough and complete examination of the electrical system before start-up the system. The electrical system including all electrical components are checked, adjusted and tested accordingly, and all protective devices are calibrated with the recommended settings. It is important that all electrical checks be conducted in the presence of qualified and competent electrical inspectors. Turn on the power for the electrical system as soon as all the necessary electrical checks are fulfilled. A full test report of the above-mentioned electrical checks/test is prepared. Equipment Start-up Upon completion of the electrical checks above, the whole plant is then scheduled for start-up. The whole system will be put on operational checks to ensure that it is fully functional and operational without any major problems. Monitor the running conditions of the equipment during the test run, adjust and rectify faults and malfunctions encountered.


March 2009 1-27

Commissioning Upon satisfactory operational test run of system and each piece of the equipment, the whole system will be ready for commissioning whereby the whole system will subject to performance test to determine compliance with the contract and specification requirements. Conduct the performance tests in accordance with the approved test format. Test results and records should be witnessed and certified by the relevant parties concerned. 1.16 PUMP TESTING Pump supplied is tested to ensure it meets the required performance specifications. Depending on the size of the pump, all large pumping units are subjected to factory test to verify its hydraulic and mechanical integrity, while it is suffice to have sampling test for smaller pumping units. Where necessary, witnessed pump testes can be carried out prior to the delivery. In the purchase of pump contract, such factory acceptance tests could be specified for pumps above 500 l/sec and/or where its application is of critical service. Where provision is allowed for in the contract, such pre-delivery inspection at the Manufacturer’s works should be encouraged for technology exposure to the technical staff witnessing the test. Pump tests at the factory generally follow the standard methodology as published by the established institutions such as BS, JIS and ANS. However, to witness a pump test at factory the engineer concerned shall be familiar with the procedure in witnessing the pump test. Typical of the guidelines is as shown in the Appendix 1.2 attached. Table below shows the tolerance values for pump acceptance test based on ISO 2548 & ISO 3555, and the latest testing standard ISO 9906

Table 1.5 Permissible Tolerance

Standard Permissible Tolerances

Pump capacity Pump head Pump Efficiency ISO 2548 Class C ± 7% of Qrated ± 4% of Hrated - 5% of rated

efficiency ISO 3555 Class B ± 4% of Qrated ± 2% of Hrated - 2.8% of rated

efficiency ISO 9906 Grade 2

(Pumps above 10kW) ± 9% of Qrated ± 7% of Hrated - 7% of rated

efficiency Comprehensive field operational tests are important as the whole entire pumping installation including the pumps, motors, controls, instruments, valves and electrical components etc will be subjected to operational tests for operational integrity and function. Any deficiency and malfunctioning of the system can easily be identified for rectification. Flow measurement may be taken for reference. Such tests are normally carried out during the commissioning stage. If the performance of the pumps installed at site becomes critical, final pump acceptance tests may be required. It is based on the field pump performance with reward/penalty clauses written into the contract for failure of the pump to perform within specified limits. 1.17 PUMPING STATION MODEL TEST Hydraulic models are essential to the design of hydraulic structures that are used to convey or control the flow of water. Model testing is recommended for pumping stations in which the geometry differs from the recommended standards as in the case of limitations due to space constraint. Good engineering practices call for model tests for all major pumping stations for pumps above 1000 l/sec and if multiple pump combinations are used. Sometimes model tests are conducted for existing pump stations to which different set of new pumps are being installed.


1-28 March 2009

The model is generally constructed to a geometric scale of 1:10. Procedures for the tests should be established prior to the test. 1.18 OPERATION & MAINTENANCE OF THE PUMPING INSTALLATION In general, pumping units are either diesel-driven or electrical-driven and different qualifications are required for the operation of ach type. In accordance with the Machinery (Person-in-Charge) Regulations 1957 L.N.150 Regulation 6 (ii) the person in charge of the fixed pumping units must hold Grade I or II Oil Engine Driver’s certificates as follows: -

Engine less than 40 hp --------- No certified driver required. Engine 40 – 100 hp ------------- 2nd Grade Driver for each shift. Engine 100 – 500 hp ------------ 1st Grade Driver for each shift.

Hitherto, electrically driven pumping units have been installed to most of the pumping stations. Electrically powered stations must be operated in accordance with the AKTA BEKALAN ELEKTRIK 1990 and PERATURAN-PERATURAN ELEKTRIK 1994 (Clauses 60, 62 & 63) In general a certified operator is not required to stop and start electrical motors but he is required if he has any other electrical duties e.g. maintenance of electrical gear. In such cases the electrician will be required to hold an Electrical Chargeman’s certificate (medium pressure) issued by Suruhanjaya Tenaga. Permission of the Suruhanjaya Tenaga must be obtained in writing before any station can be placed in the charge of an unqualified operator. If electrically unqualified operators are employed to stop and start motors only, they should be required to sign a statement that they have read and understood standing orders and will obey them. The standing orders must be explicit and state procedure to be followed if any fault in the electrical system develops. Under no circumstances must an unqualified operator attempt to trace or rectify the fault. In addition to technical qualifications detailed above and required under the Electricity Ordinance, operators shall also have the following qualifications:-

- Able to write clearly and neatly in Romanised Bahasa or English; - Have a knowledge of first aid as applied to treatment of electrical shock; - Be intelligent and trustworthy, and - Have fitter or mechanical equipment maintenance experience.

Pumping stations should be regularly visited and inspected by the Mechanical Engineer, particularly before pumping period is expected to end so that the necessary major repair work could be arranged before hand. As double cropping becomes more popular it will be increasingly necessary to ensure all equipments are in good running order before the next season commences. The civil engineering staff inspections of the pumping station should be regular during the pumping season and should include the following: -

- Inspect the master log and the daily log. The master log should be in permanent book from

and in addition to recording all running times, water level figures etc. should include all work done on the unit by fitters and workshops staff, spares fitted, and any other incident connected with the unit. It is a complete diary of the station;


March 2009 1-29

- Inspect the station and the surrounding. The station and the pumpsets should be spotlessly

clean and all tools should be hung on a tool board. The clock should be accurate and all recordings for the day logged to the time of inspection. The compound and station should be neat and tidy. Trash screens at the intake and water level gauges should be clean;

- Inspect the machinery and associated equipment for any abnormal noise and vibration, leakages etc. Seek advice from the mechanical engineer if necessary;

- After the inspection is completed a short note of the conditions found and any action necessary by the station staff should be entered in the master log and signed, and

- Pump operators especially electrical installations should fully understand the standing orders and these are given for general guidance in Appendix 5.7.

All electrical settings on protective devices should be calibrated two (2) years once as stipulated in Clause 110, AKTA BEKALAN ELEKTRIK 1990. Service of the electrical Supervising Engineer shall be engaged to conduct regular inspection to the electrical pumping installation as stipulated in Clause 67, AKTA BEKALAN ELEKTRIK 1990.


1-30 March 2009



March 2009 1A-1

APPENDIX 1A

ALIGNMENT CHART FOR FLOW IN PIPES. HAZEN-WILLIAMS FORMULA


1A-2 March 2009

APPENDIX 1B

GENERAL GUIDELINES ON PUMP WITNESS TESTS

(A) Before Departure: • Familiar with the project specifications and referenced standards; • Be familiar with the test procedures and setups in the recognized institutions; • Obtain a copy of test reports, test procedures and test setups from the manufacturer; • Approve the test setup and pump factory test reports prior to beginning the journey; • Develop a checklist based on the project specifications and referenced test standards before

departure; • Be completely familiar with the test data and compilation procedures; (B) Upon Arrival

(1) Discussion/agreement - agree on the test setup; - agree on the test procedure and standard used; - obtain photocopy of the calibration records for all test gauges, meters, motors etc; - check the calibration curves for the above; - go over the test procedure with the manufacturer to be certain all concerns have been

addressed; - role of each authorized personnel (2) Initial inspection - make note of the serial number; - note the time testing begins - pump test bed setup; - physical inspection of the pump to be tested.

(3) Pump starting - check all zero points or readings before starting the test; - check for proper running of equipments, apparatus etc. (4) Trial run

- establish duration required to reach steady state conditions; - listen for any unusual noises. (5) Test run

- observe the data recorded and confirm; - logging any events; - note the time that testing is finished for each pump.


March 2009 1A-3

(6) Computation

- spot check the calculated results; - verify the results; - check the performance curves (4 or more points); - sign each test log and obtain a copy of all the test data.

(7) Test reports - prepare the test reports on return home


1A-4 March 2009


1

CHAPTER 2 GATE DESIGN

Chapter 2 GATE DESIGN

March 2009 2-i

Table of Contents


List of Tables ................................................................................................................... 2-iii

List of Figures ................................................................................................................... 2-iii

2.1 INTRODUCTION .......................................................................................................... 2-1

2.2 TYPES OF GATES ......................................................................................................... 2-6

2.2.1 Roller Type ................................................................................................... 2-6

2.2.2 Hinged Type ................................................................................................. 2-9

2.2.3 Slide Type .................................................................................................. 2-13

2.2.4 Flap Gate ................................................................................................... 2-15

2.2.5 Stop logs and Bulkhead Gates ...................................................................... 2-17

2.3 GATE DESIGN ........................................................................................................... 2-18

2.3.1 General ...................................................................................................... 2-18

2.3.2 Loads to be Considered ............................................................................... 2-19

2.3.3 Shape of Gate Leaf, Gate Guide and Anchorage ............................................. 2-19

2.3.4 Seal Part .................................................................................................... 2-19

2.3.5 Corrosion Allowance .................................................................................... 2-19

2.3.6 Deflection of Gate Leaf ................................................................................ 2-20

2.3.7 Operating Speed ......................................................................................... 2-20

2.3.8 Lifting Height .............................................................................................. 2-20

2.3.9 Leakages .................................................................................................... 2-20

2.3.10 Hoist System .............................................................................................. 2-21

2.4 MATERIAL SELECTION ............................................................................................... 2-21

2.4.1 Materials for Hydraulic Gates ........................................................................ 2-22

2.4.2 Penstock Materials ...................................................................................... 2-22

2.4.3 Corrosion Protection .................................................................................... 2-23

2.5 GATE INSTALLATION ................................................................................................. 2-24

2.5.1 Handling During Transportation .................................................................... 2-25

2.5.2 General Installation ..................................................................................... 2-25

2.5.3 Installation of Gate Guide and Anchorage ..................................................... 2-25

2.5.4 Installation of Seal Part ............................................................................... 2-25

2.6 GATE TESTING AND COMMISSIONING ........................................................................ 2-26

2.6.1 Penstock inspection and testing .................................................................... 2-26

2.7 GATE OPERATION & MAINTENANCE MANUAL .............................................................. 2-27

APPENDIX 2A SAMPLE METHOD STATEMENT FOR TILTING GATE AND HYDRAULIC CYLINDER INSTALLATION ........................................................................................... 2A-1


2-ii March 2009

APPENDIX 2B METHOD STATEMENT FOR TILTING GATE GUIDE INSTALLATION .................. 2A-4

APPENDIX 2C TESTING & COMMISSIONING PROCEDURES FOR TILTING GATE .................... 2A-8

APPENDIX 2D OPERATION AND MAINTENANCE MANUAL – GENERAL PROPOSED CONTENTS (WHERE APPLICABLE) ............................................................................... 2A-11


March 2009 2-iii

List of Tables

Table Description Page

2.1

2.2

2.3

Corrosion Allowance for Plate Thickness

Materials Used for Gate Components

Materials Used For Penstock

2-20

2-22

2-23

List of Figures

Figure Description Page

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9(a)

2.9(b)

2.9(c)

2.10

2.11

2.12

2.13

2.14

2.15

2.16

2.17

2.18

2.19

2.20

2.21

2.22

Typical Gate Applications in DID

Spillway Gates

Barrage Gates

Headwork Gates

Headwork Gates

Tidal Control Gates

Regulator Gates

Intake Gates

Aluminium Roller Gate



Radial Gate

Radial Gate (Overflow Type)

Radial Gate (Breastwall Type)

Titling Gate (At Factory)

Tilting Gate (Installed)

Mitre Gate

Slide Gate

Cast Iron Sluice Gate

HDPE Flap Gate (Circular)

HDPE Flap Gate (Rectangular)

Rubber Flex Valve

Stoplog

Bulkhead

2-1

2-2

2-3

2-3

2-4

2-4

2-5

2-5

2-6

2-7

2-8

2-9

2-10

2-11

2-12

2-12

2-13

2-14

2-15

2-16

2-16

2-17

2-17

2-18


2-iv March 2009



March 2009 2-1

2 GATE DESIGN

2.1 INTRODUCTION For DID applications, gates are the mechanical parts installed at the various structures for water management and control purposes which may include:-

a) Storage or backing up of water for irrigation purposes b) Flood control c) Regulate and control water discharges d) Prevent sea water intrusion e) Navigation purposes

Typical usage of gates in an irrigation scheme is as shown in Figure 2.1 Applications in DID where gates are installed are as follows:-

Figure 2.1 Typical Gate Applications in DID


2-2 March 2009

a) Dam – retention of water for flood control and/or irrigation purposes (Figure 2.2)

Figure 2.2 Spillway Gates


March 2009 2-3

b) Barrage – large gated structure across the river for drainage or irrigation control purposes

(Figure 2.3)

Figure 2.3 Barrage Gates

c) Headworks - gated structure across the river for irrigation control purposes (Figures 2.4 & 2.5)

Figure 2.4 Headwork Gates


2-4 March 2009

Figure 2.5 Headwork Gates

d) Tidal Control – gated structure at drain outlets to the sea for drainage purposes and prevent sea water intrusion (Figure 2.6)

Figure 2.6 Tidal Control Gate


March 2009 2-5

e) Regulator – gated structure across the main irrigation canal for regulating water discharge into

separate canals (Figure 2.7)

Figure 2.7 Regulator Gates

f) Intake – gated control structure at dam outlets for control of flow discharge into irrigation

canals (Figure 2.8)

Figure 2.8 Intake Gates


2-6 March 2009

g) Offtake – gates to control water from headworks into irrigation canals h) Checks – gated structure across the irrigation canal to control head and flow i) Irrigation Control – gates for control of irrigation water into field channel j) Farm turnouts – small gates for control of irrigation water into the farm k) Drainage Control – gates at the drain outlets 2.2 TYPES OF GATES Gates are classified in terms of their application as follows:- a) Spillway crest gates b) Navigation locks c) Outlet control gates d) Sluice / slide gates e) Maintenance Bulkhead gates Gates may be classified in terms of their mechanical construction and the types and names of commonly used gates are as follows:- 2.2.1 Roller Type a) Fixed wheel gate (roller gate) This type of gate consists of rollers installed at both sides of the gate body. The disc or movable part of the gate is a flat structural steel plate reinforced with structural members. The rollers rotate on the rails or surface of the gate guide to move the gate body vertically. It has a low friction coefficient, enabling a large gate or a gate with great water depth to be operated with relatively small power. The hydraulic load on the gate body is transmitted to the gate guide through the rollers. The number and size of the rollers depend upon the size of the gate and the head under which it operates. To ensure water-tightness, watertight rubber seal is installed on the gate body. Figure 2.9(a), (b) & (c) shows a typical roller gate. Some common roller gate sizes used by DID are:- Aluminium Roller Gate – 3.6m X 3.6m (h), 3.6 X 3.9m (h), 3.6m X 4.2m (h)

Figure 2.9(a) Aluminium Roller Gate


March 2009 2-7

Figure 2.9(b) Aluminium Roller Gate


2-8 March 2009

Figure 2.9(c) Aluminium Roller Gate


March 2009 2-9

The disadvantages of vertical lift gates include a heavier lifting load, which requires greater hoist capacity; pier-height requirement; greater time required for gate operation and gate slots that can lead to cavitation and debris collection. b) Multistage wheel gate A multistage or multi-section gate consists of two or more sections in the same slot with variable discharge between the sections or between the bottom section and the sill. Multi-section gates can be equipped with a latching mechanism to allow its use as a single section gate. 2.2.2 Hinged Type a) Radial gate The radial gate is a segment of a cylinder mounted on radial arms that rotate on trunnions anchored to the piers. Normally the water is against the convex side of the gate. The radial gate has an upstream skin plate bent to an arc, with convex surface of the arc on the upstream side (See Fig. 2.10). Pressure is transferred from the curved face through the horizontal face support beams to the radial arms at the sides of the openings. The arms act as columns and transfer thrust to a common bearing located on either side of the gate opening. This design results in a light-weight, economical gate that can be operated with minimum effort and a comparatively small number of turns of the hand-wheel on the hoist.

Figure 2.10 Radial Gate Radial gates could be of two types of installation depending on application. The most common type is the overflow type, where the gate is designed for 1 foot of water flowing over the top of the gate. Adequate safety factors in the design prevent damage to the gate if a moderate additional overflow is increased beyond that limit for a short period of time (See Fig. 2.11). The second type is the breast wall type where a vertical wall is constructed over the top of the gate opening resulting in additional storage capacity in front of the gate. The gate has to be designed for this higher head (See Fig. 2.12).


2-10 March 2009

Some common radial gate sizes are:- 6m X 1.5m(h) 5m X 1.5m(h)

Figure 2.11 Radial Gate (Overflow Type)


March 2009 2-11

Figure 2.12 Radial Gate (Breastwall Type)

b) Bottom hinged flap gate (Tilting Gate) The tilting gate is of flat plate design that is reinforced with vertical and horizontal members and is fitted with a single torque tube across the invert. Side seal plates are mounted in the side concrete walls and resilient seals are attached to the sides of the movable disc to seal against the side seal plates. There is a seal across the hinge or bottom of the gate. (See Fig. 2.13 and 2.14).


2-12 March 2009

Figure 2.13 Tilting Gate (At Factory)

Figure 2.14 Tilting Gate (Installed)

c) Miter gate Miter gates are used mainly as lock gates for navigational control for passage of ships or boats and as such is frequently operated requiring a simple structure and reliable operation. A navigation lock requires closure at both ends of the lock so that water level in the lock chamber can be varied to coincide with the upper and lower approach channels. Miter gates are fairly simple in construction and operation and can be opened or closed more rapidly than any other type of gate. Maintenance cost is generally low. Disadvantage of this gate is that it cannot be used to close off flow in an emergency situation with an appreciable unbalanced head. Miter gates fit in the recesses in the wall in the open position. (See Figure 2.15).


March 2009 2-13

Figure 2.15 Mitre Gate

2.2.3 Slide Type a) Slide gate The slide gate is often used as a small gate (with an area of 10 m2 or smaller) because of its simple construction. The gate body is moved by sliding the water-tight surface, made of metal. The gate guide is embedded in concrete is constructed so that the pressure bearing plate supports the hydraulic load of the gate body and maintains water-tightness. Figure 2.16 shows a typical slide gate.


2-14 March 2009

Figure 2.16 Slide Gate

b) High pressure slide gate (Sluice gate) Sluice gates are normally cast iron, vertically sliding valve with bronze seat facings and all sluice gates have adjustable bronze wedges. These wedges causes the seat facings to be pressed close together thus ensuring low leakages for sluice under seating and unseating heads. Sluice gates are normally mounted over an opening in a concrete wall or on the end of a pipe. It has machined back mounting flange for mounting on cast iron wall thimbles or pipe flanges (See Figure 2.17). Sluice gates are suitable for both seating and unseating head and can be used for applications up to 60m seating head and 30m unseating head. Sluice gates have very low allowable leakages as in accordance to AWWA Specification of 1.25 l/min/m seal perimeter for on-seating head and 2.5 l/min/m seal perimeter for off-seating head.


March 2009 2-15

Figure 2.17 Cast Iron Sluice Gate 2.2.4 Flap Gate These are automatic gates that allow for flow in one direction but prevent water from flowing back through the gate. They open automatically under a back-head and close automatically under a face-head. Flap gates could be round or rectangular shape and normally of cast iron, aluminium, HDPE or fibreglass material. Flap gates consist of a cover or flap that is hinged to the body through hinge arms to open on pivot points. For good water tightness, bronze seats machined to a fine finish are furnished onto both the body and cover or rubber seats are incorporated in a groove on the body of the flap gate. Flap gates could be of the round type design suitable for wall or pipe mounted as shown in Figure 2.18 with the typical materials for HDPE Flap Gate. It could also be of the rectangular type suitable for wall mounted as shown in Figure 2.19 with material specification for each component.


2-16 March 2009

Figure 2.18 HDPE Flap Gate (Circular)

Figure 2.19 HDPE Flap Gate (Rectangular)

Another type of one direction control device for drainage outlets is the rubber flex valve (See Figure 2.20).


March 2009 2-17

Figure 2.20 Rubber Flex Valve 2.2.5 Stop logs and Bulkhead Gates For the purpose of temporary closure of a section of the waterway or channel in-front and behind the gated section for repair or maintenance of the gate stop logs or bulkhead gate is placed in guides is used normally embedded in concrete. A stoplog normally consists of a number of equal similar sections for interchange-ability stacked on top of each other. The height of each stop log section is normally limited to maximum of 2m so that its weight is not to high for its ease of installation and removal. Side and bottom rubber seals are incorporated to minimise leakage to the standard required. In order to reduce lifting loads due to friction side rollers may also be installed on each side of the stop log. Stop logs are placed and removed by gantry crane or mobile crane with the help of a lifting beam. Because the stop log and bulkhead gate is normally in a submerged condition, the lifting beam has to provide a automatic latching and unlatching mechanism to lift it from the guide. Stop logs are normally of carbon steel material with proper corrosion protection treatment and painting (See Figure 2.21).

Figure 2.21 Stoplog


2-18 March 2009

Bulkhead gates are large fabricated steel or stainless steel gates placed in guides normally embedded in concrete. It is custom-designed for size and head requirements and normally side and bottom seals are incorporated. Bulkhead gates are normally removed under balanced head conditions and as such rollers may not be required. Special design can include fill valves on the gate and seals across the top to seal on a lintel where the unit will close a submerged opening (See Figure 2.22).

Figure 2.22 Bulkhead

2.3 GATE DESIGN 2.3.1 General A hydraulic gate shall be designed with the following considerations:- a) Safety against predictable load b) Sufficient water tightness suitable with its application c) Easy and reliable operation d) High durability e) Free from any harmful vibrations during operation f) Easy maintenance A list of gate design steps could consist of the following:- a) Obtain general information on gate height, width and max. water head b) Determine design loads to be considered c) Determine spacing of horizontal girders d) Determine centroids of sections e) Determine loading carried by each girder f) Determine max. bending moment of girder and girder size


March 2009 2-19

2.3.2 Loads to be Considered Gates are designed for hydrostatic and hydrodynamic forces. In designing a hydraulic gate, the loads to be considered shall include weight of gate, hydrostatic pressure, sediment pressure, wave pressure, buoyancy, gate operating forces, wind load, changes in hydraulic pressure by flowing water and load increase due to vibration caused by changes in the hydraulic pressure. Under certain circumstances other loads such as ice pressure, snow load, effects of temperature changes and pressure during earthquake may have to be considered. In addition to water load, the designer may add 2 to 5 m of water head to the static head to account for sub-atmospheric pressures downstream of gates located in conduits/sluices. To cater for the increase in load due to vibration, approximately 10% of the static load is added and another 5% for surge effect. Gates are normally designed to close under its own weight but sometimes it may require a positive thrust for closing, in which case suitable hoists shall be installed. For hermetically sealed gates, buoyancy and uplift need to be considered as against gate weight to ensure gates can be closed under its own weight. 2.3.3 Shape of Gate Leaf, Gate Guide and Anchorage Shapes of gate leaf, gate guide and anchorage shall properly be selected depending on the purpose of its use. A hydraulic gate is likely to be exposed to overflow from the leaf top and underflow from gate bottom and this may cause the gate to vibrate excessively. These vibrations can be reduced to some extend by improving the shape of the leaf, guide and anchorage. A gate normally consists of a number of main girders placed horizontally on which the skin plate is attached. The girders are selected and spaced such that each girder takes an equal part of the total hydraulic load. Hence girders will be spaced closer for the lower section of the gate where the hydraulic load is higher and further apart for the upper section where the load is less. From considerations of rigidity of the gate structure and the span of the skin plate, recommended spacing of girders is normally between 500mm to 1,200mm. 2.3.4 Seal Part Seal design of appropriate construction and high durability seal material is important to ensure long lasting good sealing of the gate. The rubber seal should be designed to be easily replaceable, of low friction load, water-tight against some deflection and to have good durability. A proper hardness (shore hardness 40 to 80) and shape (flat, L or J type) of the rubber seal to ensure it is flexible enough to the movement and deflection of the gate leaf due to hydraulic pressures. For design purposes the coefficient between rubber seal and stainless steel plate is taken as 0.5 to 0.7 when wet and 0.9 to 1.2 when dry. The seal part of a hydraulic gate is often made of stainless steel plate with natural rubber (very strong) or synthetic rubber (atmospheric corrosion resistant) seal. The seal attachment plate should have slotted bolt holes to allow for field adjustment of the seals. The flat type and L-type are used for the bottom or side sealing of gate under low hydraulic pressure, while the J-type is used for low to high hydraulic pressure. The caisson type is suitable for high hydraulic pressure. Water tightness is obtained by utilising the hydraulic pressure acting on the rubber seal. This standard side-seal configuration provides for an increase in the sealing force in proportion to increased head and seals usually tend to leak under low head rather than high head. 2.3.5 Corrosion Allowance Where mild steel is used for gate leaf, some amount of plate thickness has to be added to cater for corrosion. The amount of corrosion allowance to be added as per Japanese standard is as follows:-


2-20 March 2009

Table 2.1 Corrosion Allowance For Plate Thicknees

Place Skin Plate Other Main Members

Water contact face or abrasion face

One Face (mm)

Both Faces (mm)

Both Faces (mm)

Hydraulic gate used in fresh water 1 (1) 2 (1) 2

Hydraulic gate used in sea water 1.5 3 2

Figure in ( ) indicates corrosion allowance for abrasion to be added where appropriate.

2.3.6 Deflection of Gate Leaf Deflection of gate leaf is set by taking into consideration the rigidity required by the structure and the safety during operation. The following are the recommended deflection for gates as per technical standards for gates and penstock by hydraulic Gate and Penstock Association:- Normal Gate 1/800 of span Slide / sluice gate 1/1200 of span Stoplog / bulkhead gate 1/600 of span Span means the distance between the supports for a fixed wheel gate and the clear span for a radial or bottom hinge flap gate. 2.3.7 Operating Speed The operating speed of a hydraulic gate is selected in accordance with the purpose of its use. The following operating speed as per technical standards for gate and penstock by Hydraulic Gate and Penstock Association is used as a guide:- a) Normal operating speed is 0.3 to 0.5 m/min. taking into account upstream and downstream

effects caused by the discharge of water b) For automatic control or some other special purpose the operating speed is slower to about 0.1

m/min. c) For navigation locks the speed is increased to 1.0 to 5.0 m/min. d) For controlling flow as for a bottom hinged flap gate (tilting gate), the closing or opening time is

usually 10 to 20 mins. 2.3.8 Lifting Height The lifting height of a hydraulic gate is determined so as to be safe against the down flowing water after the gate is lifted. Factors such as shapes and sizes of the drifting debris during a flood is to be considered. A normal clearance of at least 1.0 m is sufficient for an overflow depth of 2.5m or less and for dam design at least 1.5m is required. 2.3.9 Leakages Recommended allowable leakages for various types of gates and applications are given below. Leakage for gates with rubber seals (roller, radial, tilting gate) is 0.15 l/sec/m perimeter seal contact. For penstock/sluice gates the allowable leakage value is as stipulated in the AWWA specification for penstocks as follows:-


March 2009 2-21

on-seating < 1.25 l/min/m seating perimeter off-seating < 2.5 l/min/m seating perimeter (H < 6 m) < 1.25 + 0.205x H l/min/m seating perimeter (H >6 m) where H – unseating head in metre Testing of leakage can be either by wet test or dry test. Where wet test is permissible then actual amount of water leakage is measured as per testing & commissioning procedure Appendix 2.3. In cases where wet test is not possible then a dry test is carried out as per AWWA C501 Standard where a feeler gauge is used to measure the clearance between the rubber seal and its seal plate. The maximum allowable clearance shall be 0.102 mm (0.004 in.) 2.3.10 Hoist System Hoisting of gates could be by spindle, wire rope or hydraulic cylinder depending on type of gate, lifting height and speed, lifting load, requirement of positive closure and space availability. Operation of these hoists could be by manual, AC electric motor, DC electric motor or hydraulic power. In the design of hoist system the loads that have to be considered include weight of dead load (gate, spindle etc), wedge load (sluice gate), seal friction, roller friction, sliding friction, downpull, uplift and buoyancy. Some typical safety factors recommended by the Japanese Water Gate and Penstock Association are as follows:- Drum shaft safety factor ~ 5 times Wire rope safety factor ~ 8 times Commonly used drum shaft diameter are:- a) for 3.6m X 3.6m, 3.6m X 3.9m and 3.6m X 4.2m roller gate is 75mm b) for 5.5m X 4.0m X 9m (head) is 125mm Actual drum diameter required should be based on actual load calculations. Actuator sizing is based on total operating load and operating speed. Some typical actuator sizes for commonly installed gates are as follows and should be used as a guide only:- Aluminium Roller Gate 12’ X 14’ (h) ~ 250 Nm @ 144 rpm Penstock Gate 2m X 2m (8m head) ~ 1020 Nm @ 24 rpm 2.4 MATERIAL SELECTION Selection of the correct material for the gate in relation to the operating environment is of utmost importance to prevent corrosion. For normal fresh water mild steel with suitable corrosion protection such as paint coating may be sufficient. For more corrosive environment, materials such as stainless steel 304 or 316L, alloy aluminium, High Density Polyethylene (HDPE) or rubber should be considered.


2-22 March 2009

2.4.1 Materials for Hydraulic Gates The following are the materials normally used for various parts of hydraulic gates:-

Table 2.2 – Materials Used For Gate Components

Component Materials Standard Grade Structural parts of gate leaf (skin plate, girders, stiffeners, arms etc) Track base or embedded guide Seal seat, sill beam Gate Wheel / Guide rollers Rubber Seal

(i) Rolled steel for general structures

(ii) Stainless Steel (iii) Marine Alloy

Aluminium Rolled steel for general structures Stainless Steel Cast Iron Cast Steel Moulded natural or synthetic rubber

BS 4360, BS4, BS4848 BS 970 BS 1470 - 77 BS 4360 BS 970 BS 1452 BS 3100

43, 50 304 NE8M, NS8M 43 316 Gr 220 ASTM A27 60-30 Shore A hardness 60 to 70

2.4.2 Penstock Materials All materials used in the construction of the penstocks should have good corrosion resistant characteristics. To reduce corrosion arising from electrochemical action associated with the use of dissimilar metals, parts of the penstocks continuously in contact with the fluid should, as far as is possible, be made for metals close to each other in the electrochemical series. Penstock components should be manufactured from the basic materials listed in the table as follows:


March 2009 2-23

Table 2.3 – Materials Used For Penstock

Component Materials Standard Grade Frame and gate Stem Stem couplings Stem Guides Thrust/Operating nuts Seats Seals Pedestal Bolts, nuts and anchor bolts Handwheel Identification plate and screws

Grey cast iron Spheroidal graphite iron Stainless steel Stainless steel Spheroidal graphite iron with phosphor bronze lining Gunmetal Phosphor bronze Gunmetal Phosphor bronze Gunmetal Phosphor bronze Spheroidal graphite iron Stainless steel Grey cast iron

Stainless steel

BS 1452 BS 2789 BS 970 BS 970 BS 2789 BS 1400 BS 2874 BS 1400 BS 2874 BS 1400 BS 2874 BS 2789 BS 970 BS 1452 BS 970

220 420/12 316 S16 316 S16 420/12 LG2 CZ 114 LG2 CZ 114 LG2 CZ 114 420/12 316 S16 220 316 S16

The materials should be: a) suitable for the temperature and pressure of the fluid being handled under all operating

conditions b) compatible with the fluid and with the material of adjacent components; and c) suitable for the environment For phosphor bronze materials, they should be zinc-free, that is the zinc content should not exceed 0.05 per cent. 2.4.3 Corrosion Protection General For non-stainless steel material, corrosion damage will occur over time and can impair structural and operational capacity of gates. To minimise future structural problems and high maintenance and rehabilitation costs, resistance to corrosion must be considered in the design process. Gates are normally subject to localised corrosion (ie. Crevice corrosion or pitting), atmospheric corrosion or mechanically assisted corrosion. Prudent design and maintenance practices can minimise these corrosion.


2-24 March 2009

Corrosion mitigation can be accomplished by design considerations, by employing corrosion-resistant materials of construction, by employing cathodic protection and by application of protective coatings. Selection of type of corrosion protection is dependent on the particular environment in which the gate will operate. Design Consideration The use of acceptable engineering practices to minimise corrosion is fundamental to corrosion control. Avoid crevices where deposits of water-soluble compounds and moisture can accumulate and are not accessible for maintenance. Any region where two surfaces are loosely joined, or come in close proximity is also considered as a crevice. Jointing practices such as bolting, back-to-back angles, rough welds, sharp edges, corners and intermittent wells also create corrosion problems Protective Coating Systems Application of coating systems is the primary method of corrosion protection for gates. Coating systems include alkyd enamel, vinyl and epoxy paint systems. Painting system should follow accepted procedure as recommended by paint manufacturers to ensure good corrosion protection. The painting procedure would normally include proper surface preparation by sand blasting to SA 2.5, Cleaning of surface to remove residues, coating with primer and at least two finishing coats to the recommended thickness. A typical recommended painting scheme for steel works is as follows:- 1st coat Epoxy Primer DFT 50 micron 2nd coat Coaltar Epoxy DFT 100 micron 3rd coat Coaltar Epoxy DFT 50 micron For hot dip galvanizing protection, BS729 shall be adhered to as follows:- Material thickness Min. coating weight more than 5mm 610 g/m² (100 micron) less than 2mm 335 g/m² Metalic coatings such as thermal sprayed (metallizing) zinc, aluminium, aluminium-zinc alloys, stainless steel and chromium can be used to protect against corrosion or provide increase wear and abrasion resistance and should be considered in extreme abrasive environment. Zinc-rich coatings are widely used to provide galvanic corrosion protection to steel. Cathodic Protection Cathodic protection is often used in the more corrosive environment to supplement the paint coatings. Cathodic protection is achieved by applying a direct current to the gate from some outside source by impressed current or sacrificial anode attached to the gate. Cathodic protection introduces a low current to counteract the continuous process of removing electrons from the steel. 2.5 GATE INSTALLATION The gate assembly is a custom made equipment comprising various parts, components and accessories such as gate, guide, lifting mechanism etc. Being custom made to order on an individual basis, complete inter-changeability of all parts is not possible and as such it is essential that the equipment is carefully handled during transit, unloading, storage and installation to avoid damage or mixing up. (Refer Appendix 2A for a sample Method Statement on Gate Installation)


March 2009 2-25

2.5.1 Handling during Transportation A hydraulic gate is usually installed at a place where the transportation conditions are poor and the gate is likely to be deformed or damaged during transportation. Gate components should be transported as a large block and any component which is less rigid should be properly reinforced. Machine-finished faces should be protected with wood or other suitable material and proper paint or grease to be applied to prevent corrosion during transportation. Electric and mechanical parts should be handled carefully and not exposed to rain. Rubber seals are generally transported in a wound condition which leads to deformation and is to be unwound and kept open before installation. 2.5.2 General Installation A hydraulic gate is to be installed accurately so that its shape and dimensions can exert their functions properly as intended. The hoisting operations and water-tightness of the hydraulic gate are dependent on the proper installation of the gate. The water-tight parts should particularly be properly and carefully installed. 2.5.3 Installation of Gate Guide and Anchorage For the gate to operate smoothly, accurate installation of the gate guide and anchorage is of prime importance. For fixed wheel gate, the roller seating face for each roller is to be flush and the roller track should also be flush on the left and right and each roller should contact the roller track uniformly. Uneven roller contact causes concentrated load on specific roller only and can lead to breaking of roller and irregular operation. For radial gate, the left and right trunnion pin centres must be accurately aligned and the leaf sides rotating about this pin should slide precisely on the side guide so as to secure good water-tightness and smooth hoisting operation. Gate guides (side and invert seal plates) are usually installed in two (2) stages in the concrete ie first stage embedded guide for adjustment purposes and second stage for the finished guide surface. At the placement of first stage concrete, a box-out is made and installation of adjusting bolts or reinforcing steel bars are embedded to fix the gate guide at the required position precisely and rigidly. This first stage gate guide should not be displaced by the second stage concrete. With the gate guide installed, measurement is made for its installation dimension for reference during gate installation. (Refer Appendix 2B for a sample Method Statement on Gate Guide Installation) 2.5.4 Installation of Seal Part The purpose of hydraulic gate is to stop water and a complete shutting off is preferable but is generally difficult to achieve. However it is necessary to minimise the leak as much as possible. Leaks generally occur at the corners of a hydraulic gate and at the top or bottom joints of a multi-stage hydraulic gate. The allowable leakage limit may vary with the type of gate. A leak from the seal part is due to irregularity of the seal contact face or gap between guide members and the concrete. A leak due to incomplete contact of the rubber seals should be stopped by adjusting the protrusive level of the rubber with the rubber tightening bolts or by inserting a steel liner plate to it. Care should be taken to clean any milk cement that may adhere to the gate guide as it may damage the rubber seal.The rubber seals should be well-adjusted in the field so as to contact the gate guide under appropriate compression.


2-26 March 2009

2.6 GATE TESTING AND COMMISSIONING Gate Testing and Commissioning should comprise of:-

- inspection & testing at manufacturer’s premises (wherever possible) before delivery of the equipment to site for installation and

- site acceptance testing after complete installation.

a) Inspection and testing at manufacturer’s premises should be made and could consist of the following:-

- Material Inspection to ensure correct and approved materials conforming to specification are

used. - Dimensional inspection to ensure the gate is manufactured in conformity to those specified

in the approved shop drawings. - Workmanship and welding inspection to ascertain that gate manufacturing is in accordance

with best workshop practices including corrosion protection where applicable. - Shop trial assembly and inspection to ascertain components are properly matched and gate

hoist operating and load test should be carried out wherever possible. b) Field Inspection and testing and commissioning is conducted to ensure that all items

manufactured and installed can perform as in accordance to specification and it could comprise the following:-

- Gate operation test to ascertain it operates without bending, excessive vibration or

overheating of any components, over the maximum travel of the gate, up and down, without stopping for at least one cycle. Gate operating speed should also be measured and compared with that specified. Operation test should be carried out with the various modes of operation such as TNB power supply, generator set emergency power and manual operation. Where applicable test should also be carried out on SCADA, remote and local mode.

- Hoisting unit test for their self-locking capability by randomly stopping the lifting and lower operation at any lifting position.

- Test the effective functioning of all safety devices such as limit switches, torque limit control etc.

- Leakage test to demonstrate the water tightness of the gate by subjecting the gate to maximum head difference as specified in the specification and measuring the leakage rate.

Refer to Appendix 2C for Sample Gate Testing & Commissioning Procedure 2.6.1 Penstock inspection and testing All penstocks should be inspected by the Engineer at the manufacturer’s works and should be tested in the presence of the Engineer. Before final assembly, all seating and wedging surfaces should be cleaned thoroughly of all foreign materials and final adjustments made. With the gate fully closed, the clearance between seating faces should be checked with a 0.10 mm thickness gauge. If the thickness gauge can be inserted between seating faces, then the wedging devices must be re-adjusted or the gate or frame or both re-machined until insertion is no longer possible. In the event of re-machining, clearances should be checked again as stated above.


March 2009 2-27

After completion of assembly, all seating and wedging surfaces should be cleaned thoroughly of all foreign materials and final adjustments made. The gate should then be operated from fully closed to fully open position to verify that the assembly is functioning properly. Where electric motor actuators are provided, the complete assembly of penstock and actuator should be tested. 2.7 GATE OPERATION & MAINTENANCE MANUAL It is of utmost importance that for each and every Drainage and Irrigation Project that is completed, proper Operation and Maintenance Manual has to be prepared by the Contractor and supplied to DID in proper bound copies before handing over and issue of Certificate of Practical Completion. The Operation and Maintenance Manual should contain Operating and Maintenance Instructions, Material schedules and drawings in sufficient detail for DID to identify, assemble, maintain, dismantle, re-assemble and adjust all components of the gates. Operating and Maintenance Instructions should provide step-by-step procedures for erection, testing & commissioning, operation, maintenance, dismantling and repair. A separate section of the Manual should contain detail description, construction and operation of each equipment complete with relevant manufacturers’ catalogues and drawings. A recommended content list of the Operation and Maintenance Manual is as follows:- a) Introduction – General Description of Gate structure, Overall Plant & Equipment description and

List of suppliers and contractors b) Detail Description of Plant and Equipment c) Gate Operation d) Gate Maintenance & Inspection e) Gate Component/ Equipment Trouble Shooting f) Drawings and electrical/Hydraulic Circuits g) Manufacturers’ Catalogues, Technical Data and Information h) Manufacturers’ Operation and Maintenance Instructions i) Manufacturers’ Recommended Spare Parts Lists j) Factory and Site Test Reports k) As-Built Drawings. Refer to Appendix 2D for a sample of the Detail Content of the Operation and Maintenance Manual.


2-28 March 2009



March 2009 2A-1

APPENDIX 2A

SAMPLE METHOD STATEMENT FOR TILTING GATE AND HYDRAULIC CYLINDER INSTALLATION

TABLE OF CONTENTS

1.0 GENERAL 2.0 SCOPE 3.0 REFERENCE 4.0 RESPONSIBILITIES 5.0 REFERENCE DRAWING 6.0 EQUIPMENTS & MACHINERIES REQUIRED 7.0 MANPOWER 8.0 SEQUENCE OF WORK 9.0 METHOD OF MEASUREMENT 10.0 APPROVAL 11.0 SAFETY STATEMENT 12.0 QUALITY


2A-2 March 2009

1.0 GENERAL This procedure briefly describes the work involved in the mechanical equipment installation. Quality control at various stages of the installation will ensure that the installed products will fulfill the requirement of the contractual specification. 2.0 SCOPE The work covered by this Section shall include all labour, material, equipment, permits, and services necessary for the execution of mechanical equipment installation and related work, complete in accordance with the drawings and specification for the Project. 3.0 REFERENCE 1) Design Standard BS 449, USBR Or JIS. 4.0 RESPONSIBILITIES The Project Manager shall be responsible for the whole work. The Construction Manager and Project Engineer shall assist Project Manager in executing the works. The Supervisor shall be based full time at site in monitoring the works. 5.0 REFERENCE DRAWING List of relevant reference drawings 6.0 EQUIPMENTS & MACHINERIES REQUIRED Hydraulic mobile crane, generator set, welding set, scaffolding, power tools. 7.0 MANPOWER

Trade Engineer Supervisor Foreman Fitter Welder Helper No. 1 1 1 2 1 2

8.0 SEQUENCE OF WORKS Receiving Equipment Delivery a) Check all in-coming materials with corresponding delivery order and packing list to ensure

quantity and quality are in conformance. b) Inspection of materials as per requirement of Inspection and Test Plan. c) Store all equipment in proper manner for easy identification and issuance.


March 2009 2A-3

Installation Work Tilting Gate and Hydraulic Cylinder a) Assemble the various parts for the gate, namely, the side seals, shaft and bearing. b) Before lowering the gate into position, it is prudent to grease the seals in order to protect them

from damage. c) Lower the gate into position by using of a mobile crane and locate the bearing blocks into the

prepared anchor bolts as shown in the drawings. Finally, tighten bolts. d) After that the gate seals can be installed. e) Next, install the hydraulic cylinders to the cylinder pivot and locate the assembly at the prepared

hydraulic pivot anchor site. Tighten the bolts. f) Finally, attach the hydraulic arms to their respective brackets on the gate.

9.0 METHOD OF MEASUREMENT The total numbers of equipment to be installed. 10.0 APPROVAL All documents or drawings, which are stated within this method statement, shall be approved or reviewed by consultant prior to installation works. 11.0 SAFETY STATEMENT Refer to Job Safety Analysis 12.0 QUALITY All inspection shall be in accordance to the approved Inspection and Test Plan.


2A-4 March 2009

APPENDIX 2B

METHOD STATEMENT FOR TILTING GATE GUIDE INSTALLATION

TABLE OF CONTENTS 1.0 GENERAL 2.0 SCOPE 3.0 REFERENCE 4.0 RESPONSIBILITIES 5.0 REFERENCE DRAWING 6.0 EQUIPMENTS & MACHINERIES REQUIRED 7.0 MANPOWER 8.0 SEQUENCE OF WORK 9.0 METHOD OF MEASUREMENT 10.0 APPROVAL 11.0 SAFETY STATEMENT 12.0 QUALITY


March 2009 2A-5

1.0 GENERAL This procedure briefly describes the work involved in the mechanical equipment installation. Quality control at various stages of the installation will ensure that the installed products will fulfill the requirement of the contractual specification. 2.0 SCOPE The work covered by this Section shall include all labour, material, equipment, permits, and services necessary for the execution of mechanical equipment installation and related work, complete in accordance with the drawings and specification for the Project. 3.0 REFERENCE [1] Design Standard BS 449, USBR Or JIS. 4.0 RESPONSIBILITIES The Project Manager shall be responsible for the whole work. The Construction Manager and Project Engineer shall assist Project Manager in executing the works. The Supervisor shall be based full time at site in monitoring the works. 5.0 REFERENCE DRAWING Relevant reference drawing 6.0 EQUIPMENTS & MACHINERIES REQUIRED Hydraulic mobile crane, generator set, welding set, scaffolding, power tools. 7.0 MANPOWER

Trade Engineer Supervisor Foreman Fitter Welder Helper No. 1 1 1 2 1 2

8.0 SEQUENCE OF WORKS Receiving Equipment Delivery a) Check all in-coming materials with corresponding delivery order and packing list to ensure

quantity and quality are in conformance. b) Inspection of materials as per requirement of ITP c) Store all equipment in proper manner for easy identification and issuance.

Installation Work Tilting Gate Guide Installation The gate guides for the tilting gates consist of:- a) The sill beam b) The gate side seal guide or wall plate which runs vertically.


2A-6 March 2009

a) Sill Beam i) There are two stages to the sill beam installation, namely, 1st stage and 2nd stage concreting. ii) The twagger palate (2nos) are installed during the 1st stage, followed by the 2nd stage

installation of the sill beam proper. iii) The sill beam for the gate consists of composite SS316 beam sufficiently stiffened and

backed onto mild steel members for rigidity.

b) First stage installation i) Locate the twagger plates as indicated in the drawings. Tack weld the twagger plates to the

rebars once their positions are established. Achievement of accuracy to +/– 10mm is acceptable.

ii) Process with handing over for the purpose of grouting. c) Second stage installation i) Locate the sill beam as indicated in the drawings. Ensure that the sill beam I located in the

right alignment and at the correct level. Level instruments and spirit levels may be used. ii) Process to secure the sill beam to the twagger plates by the means of welding the threaded

anchor blots to them. Do regular checks on the sill beam location as welding progresses to confirm there has been no displacement. Slight adjustments can still be made using the threaded anchor blots. Maintain accuracy to + or – 3mm or better.

iii) The guides are now ready for 2nd stage concreting. d) Wall Plate i) There is only one stage for the wall plate installation due to its shape and size. The wall

plates for all the bays are erected at the same time as they have to be tied together for rigidity, prior to formwork installation and concreting.

ii) Locate the guide plates (wall plates) as shown in the drawings. Proceed to secure the wall plates in their positions by means of welding the two plates (wall plates of adjacent bays) on their back, using spacer bars. They can also be tack welded onto some of the rebars to increase rigidity.

iii) Next, install the holding frame by means of rawl plugs in the middle of the bay (the holding frame is a special jig designed to give rigidity to the gate guide prior to concreting)

iv) After ensuring that the wall plates are vertical (by means of the theodolite, spirit level or plumb- bob), tack weld the plates to the holding frame to achieve stability by means of tie-rods. Do regular checks on the position of the wall plates as welding progresses to ensure there is no displacement.

v) Make the final check and proceed with concreting. Removal the holding frame after the demoulding of the formwork. Ensure rawl plugs are properly removed and the floor surface made good.

vi) Grind off tie-rod and restore surfaces to their original condition. 9.0 METHOD OF MEASUREMENT The total numbers of equipment to be installed. 10.0 APPROVAL All documents or drawings, which stated within this method statement, shall be approved or reviewed by consultant prior installation works.


March 2009 2A-7

11.0 SAFETY STATEMENT Refer to the Job Safety Analysis 12.0 QUALITY All inspection shall be in accordance to the approved Inspection and Test Plan (ITP).


2A-8 March 2009

APPENDIX 2C

TESTING & COMMISSIONING PROCEDURES FOR TILTING GATE

TABLE OF CONTENTS 1.0 PURPOSE 2.0 INTRODUCTION 3.0 GATE OPENING AND GATE STOPPING IN INTERMEDIATE POSITION 4.0 FULLY CLOSING OF GATE, IN CONTINUOUS OPERATION, FROM FULLY OPENED

POSITION 5.0 FULLY OPENING OF GATE, IN CONTINUOUS, FROM FULLY CLOSED POSITION 6.0 OPERATION OF GATE BY USING HANDPUMP 7.0 LEAKAGE TEST


March 2009 2A-9

1.0 Purpose To set the guideline or reference through the BS 449 or JIS specification for Site testing and commissioning after sending to client. 2.0 Introduction The testing and commissioning for the Tilting Gate and hoist are conducted under the wet condition. Control for the gate operation will be carried out via Local Control Panel. The purpose of the test is to simulate the gate operation. The tests for the Tilting Gate and hoist consist of the following: a. Gate opening and gate stopping in the intermediate positions b. Fully closing of gate, in continuous operation, from fully opened to fully closed position c. Manual operation of gate using hand pump d. Leakage test 3.0 Gate Opening and Gate Stopping in Intermediate Position The purpose of the test is to verify the gate is working well in response to the “OPEN” command and “STOP” command selected in the Local Control Panel. Procedures of the test are as follow: a. Switch the Local/Remote/Scada selector in MCC panel to “LOCAL”. b. Switch on the “OPEN” push button in Local Control Panel. The hydraulic system will be energized

to make the hydraulic cylinder to open the gate. c. After confirming that the gate is lowering, stop the gate by switching on the “STOP” push button

in the intermediate position. d. After that, lower the gate again by using “OPEN” push button. 4.0 Fully Closing of Gate, In Continuous Operation, From Fully Opened Position The purpose of the test is to verify: a) Gate is capable of closing completely from fully opened position. b) Gate is capable of stopping automatically after reaching the fully closed position. c) The operating speed of gate from fully opened position to fully closed position is around

450mm/min. Procedures of the test are as follows: a) Gate is in fully opened position. b) Switch the Local/Remote/Scada selector in MCC panel to “LOCAL c) Switch on the “CLOSE” push button in Local Control Panel. The hydraulic system will be

energized to make the hydraulic cylinder to close the gate. d) Measure the gate operating time from fully opened to fully closed position. Operating speed can

be determined by dividing total operating time with 4m distance. e) Let the gate stop automatically. f) Check the position of gate to confirm that gate is in fully closed position.


2A-10 March 2009

5.0 Fully Opening of Gate, In Continuous Operation, From Fully Closed Position The purpose of the test is to verify: a) Gate is capable of opening completely from fully closed position. b) Gate is capable of stopping automatically after reaching the fully opened position. c) The operating speed of gate from fully closed position to fully opened position is around

300mm/min. Procedures of the test are as follow: a) Gate is in fully closed position. b) Switch the Local/Remote/Scada selector in MCC panel to “LOCAL c) Switch on the “OPEN” push button in Local Control Panel. The hydraulic system will be energized

to make the hydraulic cylinder to open the gate. d) Measure the gate operating time from fully closed to fully opened position. Operating speed can

be determined by dividing total operating time with 4m distance. e) Let the gate stop automatically. f) Check the position of gate to confirm that gate is in fully opened position. In fully opened

position, the gate shall sit on the top of gate seat. 6.0 Operation of Gate by Using Hydraulic Hand pump The purpose of the test is to confirm the functioning of the manual hand pump mechanism. Procedures of the tests are as follow: a) Open the gate by using hand pump which is located on the Power Pack of the hydraulic unit. The

gate shall be lowered down by at least 150mm height. b) After this, close the gate by using hand pump. The gate shall be raised up by at least 150mm

height. 7.0 Leakage Test The purpose is to verify that the leakage shall not exceed 0.15 litre per second per metre perimeter length of seal. Procedures of the tests are as follow: a) Raise the gate until fully closed position. b) Place the stoplog leaves insides the downstream stoplog grooves. c) Then, pump out the water between the gate and downstream stoplog. d) Measure the leakage water for 5 minutes, the allowable leakage should be less than 637 litres.


March 2009 2A-11

Appendix 2D

OPERATION AND MAINTENANCE MANUAL – GENERAL PROPOSED CONTENTS (WHERE

APPLICABLE)

Volume I Section 1 Introduction 1.1 General description of structure & location 1.2 Overall plant & equipment description 1.3 List of suppliers and sub-contractors Section 2 Description of Plant & Equipment 2.1 Gate system 2.2 Hoist system 2.3 Stoplog system 2.4 Electrical System 2.5 SCADA and automation system 2.6 Ancillary and auxiliary plant & equipment Section 3 Gate Operation 3.1 Manual operation procedure 3.2 Local automation operation procedure 3.3 Remote automation operation procedure 3.4 Standby generator set manual operation procedure 3.5 Standby generator set automation operation procedure 3.6 Operator’s inspection checklist and record books 3.7 Standing instruction 3.8 Safety instruction and checklist 3.9 System site testing and commissioning report Section 4 Maintenance and Inspection 4.1 Maintenance and inspection schedule 4.2 Inspection checklist for gate and hoist system 4.3 Inspection checklist for electrical system 4.4 Inspection checklist for standby generator system 4.5 Inspection checklist for SCADA and automation system 4.6 Inspection checklist for other system 4.7 Breakdown maintenance procedure 4.8 Servicing maintenance checklist and procedure 4.9 Scheduled maintenance procedure 4.10 Safety instruction and checklist


2A-12 March 2009

Section 5 Trouble-shooting 5.1 General trouble shooting notes 5.2 Trouble shooting for SCADA and automation system 5.3 Trouble shooting for electrical system 5.4 Trouble shooting for generator set 5.5 Trouble shooting for gate and Hoist system 5.6 Trouble shooting for stoplog system 5.7 Trouble shooting for gantry crane Section 6 Drawings and Circuits 6.1 Gate and hoist system layout drawings 6.2 Electrical system component drawings 6.3 Electrical system control circuit 6.4 Automation control diagram and circuit Volume II Compiled References Section 1 Manufacturers’ Catalogue, Technical Data and Information 1.1 Gate components 1.2 Hoist system components 1.3 Stoplog components 1.4 Gantry crane 1.5 Electrical system components 1.6 Ancillary and auxiliary plant & equipment Section 2 Manufacturers’ Operation and Maintenance Instruction Manual 2.1 Hoist equipment 2.2 Gantry crane 2.3 Ancillary and auxiliary plant & equipment 2.4 Generator diesel engine 2.5 Gantry crane Section 3 Manufacturer’s spare part lists 3.1 Gate and hoist components 3.2 Gantry crane components 3.3 Generator components 3.4 Ancillary and auxiliary plant & equipment Section 4 Factory and Site Test Reports 4.1 Gate and hoist system 4.2 Stoplog system 4.3 Gantry crane 4.4 Electrical system components 4.5 Generator system 4.6 SCADA and automation system 4.7 Miscellaneous plant & equipment 4.8 Factory test certificates 4.9 Site test certificates


March 2009 2A-13

Section 5 As built Drawings [A3] 5.1 List of drawings 5.2 Gate shop drawings 5.3 Hoist shop drawings 5.4 Stoplog shop drawings 5.5 Gantry crane shop drawings 5.6 Electrical system shop and control drawings 5.7 Ancillary and auxiliary plant & equipment system drawings 5.8 SCADA and automation system drawing


2A-14 March 2009


CHAPTER 3 GROUND WATER FACILITIES

Chapter 3 GROUND WATER FACILITIES

March 2009 3-i

Table of Contents


List of Figures ........................................................................................................................ 3-ii

3.1 INTRODUCTION .......................................................................................................... 3-1

3.2 DRILLING RIGS AND OTHER RELATED EQUIPMENT ....................................................... 3-1

3.3 SAFETY OPERATION & RULES ...................................................................................... 3-2

3.4 SITE SELECTION AND PREPARATION ............................................................................ 3-2

3.5 RIG FOUNDATION AND LEVELLING ............................................................................... 3-3

3.6 MUD MIXING ............................................................................................................... 3-3

3.7 SAMPLING AND LOG RECORDING ................................................................................. 3-4

3.8 BOREHOLE TEST ......................................................................................................... 3-5

3.8.1 Depth measurement ...................................................................................... 3-5

3.8.2 Directional survey ......................................................................................... 3-6

3.8.3 Verticality survey .......................................................................................... 3-6

3.8.4 Geophysical logging ...................................................................................... 3-6

3.8.5 Gamma log ................................................................................................... 3-7

3.8.6 Calliper logs .................................................................................................. 3-7

3.8.7 Fluid flow measurement ................................................................................ 3-7

3.9 DESIGN OF GROUND WATER WELL .............................................................................. 3-7

3.10 INSTALLATION OF CASING .......................................................................................... 3-7

3.11 WELL DEVELOPMENT ................................................................................................... 3-8

3.12 PUMPING TEST ........................................................................................................... 3-8

3.12.1 Reason for test pumping................................................................................ 3-8

3.12.2 Method of measuring flow rates ..................................................................... 3-8

3.12.3 Test pumping procedures .............................................................................. 3-8

3.12.4 Testing low yield bores .................................................................................. 3-9

3.12.5 Testing high yield bores ................................................................................. 3-9

3.13 PUMPING DESIGN AND INSTALLATION ......................................................................... 3-9

3.14 OPERATION AND MAINTENANCE MANUAL ..................................................................... 3-9

3.15 REPAIR AND SERVICE MANUAL .................................................................................. 3-10


3-ii March 2009

List of Figures

Figure

Description Page

3.1

3.2

3.3

3.4

3.5

Typical Drilling Equipment Set Up

Mud Mixing

Mud Balance

Sampling for Flow

Typical Directional Survey

3-3

3-4

3-4

3-5

3-6


March 2009 3-1

3 GROUND WATER FACILITIES

3.1 INTRODUCTION The first ground water exploration program introduced by the Department was in 1980. Two set of drilling rigs were purchased from Japan for the purpose of ground water exploration for paddy and cash crop irrigation. Two teams of personnel were set up, comprising of Hydrologist, Geologist, Engineers, Technical Assistants, Technicians, Mechanics and general workers. Consultants from Australia were employed which act as Master Driller to train the drilling team. In 2003 another drilling rig locally made was purchased. Since then, more than 300 ground water wells were sunk mainly for cash crop such as tobacco and vegetables. The wells were located in all states, and many are in Kelantan and Terengganu where ground water quantity is more likely adequate for the purpose of irrigation. 3.2 DRILLING RIGS AND OTHER RELATED EQUIPMENT The drilling rigs and other related equipment to be highlighted in this manual are strictly for the purpose of ground water well, top drive swivel, air and mud direct circulation drilling. Equipments used are as listed below: a) Resistivity survey equipment

i) Resistivity sounder ii) Global positioning system iii) Measuring tape iv) Land survey equipment v) Other related data recording instrument vi) Resistivity reports (exploration well & observation well)

b) Drilling equipment

i) Drilling rigs ii) Drill rods iii) Drill bits iv) Air compressor v) Mud mixing hopper vi) Vertical balancing equipment vii) Soil (cutting) sampling container viii) Water source and pump ix) Showel & other equipment

c) Well construction equipment i) Steel and PVC casing (pipe) ii) Well screen iii) Welding set iv) Torch cutting equipment

d) Well testing equipment

i) Well sounder ii) Well radius calliper


3-2 March 2009

e) Pumping test equipment

i) Camping facilities ii) Flow meter iii) Pump sets iv) Water level meter v) Diesel generator set

f) Well commissioning

i) Ground water multistage pump ii) Prime mover iii) Well cap

g) Fishing tools 3.3 SAFETY OPERATION & RULES Rig cleanliness and tidiness offer many benefits: - Wear and damage is readily detected. - Clean tools and surfaces cease to present hazards to movement of crew members. - Tools come readily when required to perform work properly. When making inspection on the rig, check that safety chains are fitted to each end of the hoses, particularly the Kelly or swivel hose and those conveying compressed air. Ensure that fire extinguishers are checked regularly and are in good condition. Safety belts are essential for those working at height. Personal protective equipment must be available and in good condition, such as head protection, foot protection, eye protection, hearing protection, hand protection, respiratory protection and etc. 3.4 SITE SELECTION AND PREPARATION In all these cases, the search is for the fluid trapped or contained in the permeable formation. The proper well location should be determined by a qualified hydrologist or experienced water well contractor based on a study of the location and test drilling. Well should be located to produce the maximum sustainable yield possible as well as to protect the water contamination. A drill site is not just a location. The driller has to convert it into workplace equipped with all the drilling equipment set up and arranged to make the job safe and easy. The driller should inspect the site and operation. The rig and camp must be set up to ensure: - Safe working and living conditions. - Efficient drilling operations.


March 2009 3-3

Fig. 3.1 Typical Drilling Equipment Set Up 3.5 RIG FOUNDATION AND LEVELLING Setting up the rig correctly in the first place means getting the job done without unnecessary delays which are often the result of poor planning. The rig must be set up on level ground. A level area is also needed for setting up the drill pipe. Excavated mud pit must be located correctly in relation to the hole, the slope of the surface and position of the mud pump. With the rig aligned in desired direction, it is manoeuvred to place the rig directly over the hole. The jacks are then lowered to level the drill. Care is necessary to move the jack a little at a time to avoid tipping the rig over. Masts are raised hydraulically as guided by the manufactures manual. Verticality of the masts must be checked to ensure that the bore hole to be drilled stands vertical. 3.6 MUD MIXING Bentonite mud has been proven satisfactory for supporting the hole. Bentonite to be used for hole stabilisation must be hydrated fully before being added to the hole. When mixing anew batch of mud, the fresh water and mud material are mixed either by using a mud hopper paddle type mixer. Rotary drilling in unconsolidated formation, the mud density shall be 0.8 to 1.2 and for consolidated formation from 0.8 to 2.5. When bentonite mud is in use, the salinity of the mud should be lower than any likely aquifer waters and the ph should be in the range of 9.0 to 10.


3-4 March 2009

Testing for specific gravity can be achieved by using mud balance which consist of the balance arm, the lid for mud cup and the base which support the fulcrum

Fig. 3.2 Mud Mixing

Figure 3.3 Mud Balance 3.7 SAMPLING AND LOG RECORDING The engineer, geologist or client relies heavily on the information provided by the driller. The drill log reveals the full history of the full drilling operations and variations in the formation drill. The information log by the driller therefore should be accurate and truly representative of the hole or site conditions. The information fall into three broad categories: - The strata penetrated. - The actual occurrences. The driller may see, hear, feel, smell or even sense that something has

occurred or occurring. - The driller interpretation. The driller’s log must record this information and conclusion. The event

of occurrences covered by the driller’s log fall in to three categories: - Machine behaviour - Borehole behaviour - Formation fluid behaviour Many tasks are simplified if we have check list to remind us of the point covered. Printed form for driller’s log is a type of checklist.


March 2009 3-5

Often the value of information obtained can be improved considerably by a simple change in sampling methods. Qualities desired in chip sampling: - Sampling interval identified accurately and recorded - Sample free of contamination from material from other depth. - Sample not contaminated or change by drilling action or fluids. - Large clean chips - All chips including fines covered. More frequently, samples are required to permit positive identification of the rock types penetrated.

Fig. 3.4 Sampling for Flow 3.8 BOREHOLE TEST 3.8.1 Depth measurement Hole depth is the first measurement for the driller. There are several methods of measuring hole depth in common use by the driller. These two methods give acceptable accuracy: - Measurement of the suspended drill string using a tape. - Measurement counting and totalling the number of precise length drill rods pipe. Typical hole zero is at the natural surface, at the top of the casing collar, at the top of rotary table, or at the rock face (underground). Once decided upon, the hole zero becomes the starting points of all measurements and may be referred to as the ‘collar level’ or ‘drilling datum’.


3-6 March 2009

3.8.2 Directional survey A drill bit is most likely to cut a hole which is neither vertical nor straight. This being the case, it is most important that we know exactly where the hole is and in what direction the hole is heading. One of the following methods can be applied: a) by a survey of selected points in the hole to determine exactly where the hole is at that point

relative to collar of the hole. b) by a survey which measures the exact direction of the hole, at selected points.

Fig. 3.5 Typical Directional Survey

c) By a survey which measures the direction of the hole at the collar, and then at the selected

points down the hole. When surveying a well, the emphasis is placed on the deviation angle (or drift angle) reading. 3.8.3 Verticality survey The mirror observation method can be used for checking verticality, if a plum-bob is lowered down the hole. By checking the position of the plumb line at the collar of the hole when the bob is observed to just touch the wall, a rough check is made. 3.8.4 Geophysical logging In most cases, if electrical or other logging probes are to be run in a hole, a logging machine will be brought to the site, set up and run by a logging crew. The driller will play the part of rescuing the hole if anything goes wrong during the logging.


March 2009 3-7

Down hole logging is usually aimed at providing more information on the formations penetrated by the hole than can be gained from the drilling. The formation characteristics will have been changed to some extend by the drilling. The presence of the hole fluid in it will distort the results of the measurements of formation characteristics. Invasion of the formation by drilling fluids must be restricted. Wall cakes must be thin and stable. The drilling fluid must be of drilling solid. Resistivity is measured in OHM-meter. The resistivity of a material can be used to help identify the material. When the log is recorded, the logging operator will be able to provide the driller with his figure for depth of casing, borehole and major formation changes. General interpretations depend on these points: - Low resistivity is usually associated with saturated formations and saline water - Medium resistivity may be indicatives of fresh water sand or porous rock - High resistivity is exhibited by dense and impermeable rocks ‘Normal’ Resistivity Logs are recorded using one current electrode and, at least, one potential electrode down the hole. 3.8.5 Gamma log Gamma ray log records the natural radiation of the formations. It is easy to run and can be very helpful to the driller, particularly the water well driller. The gamma log has the advantages of being able to record useful information in dry and cases holes where electric logging method are useless. They are especially useful in providing a log of an old hole. The gamma log usually distinguishes between aquifer (sand) and no water product beds (clays) in unconsolidated formations. 3.8.6 Calliper logs The calliper logs measures the diameter of the borehole. In some cases, it will detect casing couplings and reveal the position of the screens. 3.8.7 Fluid flow measurement Measurement of flow, up or down a borehole is usually done by a propeller type flow meter 3.9 DESIGN OF GROUND WATER WELL Proper well design, in addition to determining the depth and diameter for best yield, includes casing selection, selecting an appropriate intake section, procedures for well development, testing, and disinfection. Well design guidelines: - Design by professional groundwater engineer - Distant requirement for the target user - Choose materials that will provide good service with price consideration. - Design and select screens and construction steps under same priorities. 3.10 INSTALLATION OF CASING Casing is used in water well to provide a stable hole, to seal the walls of the hole to exclude undesirable water. In pump well casing is also to accommodate pumping equipment. Casing in pumped water well must also have a sufficient diameter to accommodate pumping equipment, strength to withstand during installation and use, ability to resist corrosion and other deterioration.


3-8 March 2009

Steel casing offers superior strength and resistance to mechanical damage. Plastic and fibre-composite casing materials are corrosion resistant and structurally durable when installed properly. Professional engineer or experienced driller should carry out the following job: - Design of casing string - Holding casing in position - Preparation for running casing - Running the casing string 3.11 WELL DEVELOPMENT Well development should consider the following: - Type of development - Principle of development - Washing and back washing - Bailer and plunger pump - Airlift development - Mechanical surging - Hig velocity jetting tools - Finishing the well construction 3.12 PUMPING TEST 3.12.1 Reason for test pumping There are two main reasons for conducting a pump test: - Construction practiced to produce well is efficient. - To determine the optimum long term yield of a well, what level the pump suction or intake

should be set to maintain the optimum yield. 3.12.2 Method of measuring flow rates One important requirement of any pumping test is the ability to accurately determine the rate of flow from the bore. This can be done in several ways: - Measure in a known volume container - Weir board - Orifice bucket - Orifice meter - Flow meter 3.12.3 Test pumping procedures Test pumping is carried out by pumping from the bore at a constant rate and at the same time measure the water level in the pumped bore at prescribes times in order to check that pumping rate is constant to within about 10%. Should the water level inside the pump bore fall below the pump suction level, and the pump starts sucking air, the test should be discontinued and be carried out at the lower discharge rate after the water level has recovered.


March 2009 3-9

The best method of measuring the draw down is using the draw down meter. On completion of pumping test, it is necessary to record the water level so that draw down can be checked. If the water level fails to recover fairly close to the original SWL (Standing Water Level) after the period of time similar to the duration of pumping, it is suggested that the recharge is not sufficient to meet the demand. 3.12.4 Testing low yield bores Low yield bores such as stock and domestic can be tested by any of the following methods. However it should be recognised that test pumping is the most accurate method: - Bailer test - Airlift test - Single stage pumping Single stage pumping, the process is performed or conducted by inserting a submersible or shaft driven pump in a bore. A minimum test period for single stage test is between 6 to 12 hours. It may be necessary for the driller to do few trial pumping runs, and preset the pumping equipment so that it will start at and maintain the required rate. Continuity pump test can be carried out up to 72 hours. For further details, the SOP (Standard Operation Procedure) of the particular drilling equipment should be referred to. 3.12.5 Testing high yield bores Pumping water for a week is necessary. It is essential to do multistage of pump test water levels and discharge rate and the time taken for each measurement are recorded through the test. 3.13 PUMPING DESIGN AND INSTALLATION Low pressure pump- A centrifugal pump provides high volume flows suited to large diameter holes. It will not provide the pressures necessary for deeper well. Centrifugal pump requires little maintenance. The stuffing box or gland will require adjustment and re-packing. The bearings will require greasing and the impeller may also be subjected to wear. Medium pressures screw pump provide positive displacement pumps, pumping at medium pressures. Helical screw pumps require adjustment of the gland and, at longer interval, replacement of the rotor and drive link parts. High pressures- multi stage pump, larger diameter impellers provide greater output. Adding stage provides greater pressure. Pumps that have to overcome greater vertical head have more stages than pumps working against lesser heads. 3.14 OPERATION AND MAINTENANCE MANUAL Detailed specifications, diagrams, instructions and recommendation are provided in manufactures manuals and bulletins. Most suppliers provide manuals which are an important reference when inspecting the equipment and gives instruction on service/ maintenance requirements. Drillers should ensure that they have all equipment manuals on site for easy reference in case of problems or when ordering replacement parts.


3-10 March 2009

3.15 REPAIR AND SERVICE MANUAL Inspection establishes a definite procedure for recognising changes in appearance, sound and feel. Inspections have two types: a. Continuing- A continuous monitoring of the operation of the equipment. b. Periodic- A regular check of certain features Inspection involves more than looking at the equipment and checking a few gauges or indicators. The driller must have a lot of knowledge and understanding about his rig and equipment before he can carry out any worthwhile inspection. The driller must: - know the correct condition of the equipment and correct gauge readings, - understand how the equipment works and to know where to look for critical wear or other

deficiencies, - understand stresses in the components to assess how safe they are, - know the safe way to handle all tools and equipment and, - keep the rig clean and tidy so that inspections can be made easily and effectively Some features require daily attention, others are service frequently. As well as following the service schedule for the rig as set out in the manual, a driller will make daily check on: - Rig stability - Rig position - Mast vertically - Condition of mast, wire ropes and hoses - Condition of hole collar - Fluid level in the hole - Stock of fuel, lubricants an drilling materials - Availability of fishing and servicing tools to suit equipment currently in use or likely to be used. A driller’s programme of ‘continual inspection’ of the equipment will include checks and observation of gauges, dials, indicators.

CHAPTER 4 OCCUPATIONAL SAFETY AND HEALTH MANAGEMENT SYSTEM

Chapter 4 OCCUPATIONAL SAFETY AND HEALTH MANAGEMENT SYSTEM

March 2009 4-i

Table of Contents


4.1 SAFETY AND HEALTH .................................................................................................. 4-1

4.2 GENERAL SAFETY AND HEALTH AWARENESS AND REQUIREMENT .................................. 4-2

4.3 OCCUPATIONAL SAFETY AND HEALTH ACT ................................................................... 4-4

4.3.1 Occupational Safety and Health Check List ...................................................... 4-5

4.4 ELECTRICITY SUPPLY ACT ........................................................................................... 4-6

4.5 ELECTRICITY REGULATIONS ........................................................................................ 4-6

4.6 REGISTRATION OF ENGINEERS ACT ............................................................................. 4-7

4.7 UNIFORM BUILDING BY – LAWS, FACTORY & MACHINERY ACT, FIRE SERVICES REQUIREMENTS .......................................................................................................... 4-7

4.7.1 Firefighting System Safety Checklist ................................................................ 4-7

4.7.2 Machinery Safety Check List ........................................................................... 4-8

4.7.3 Building Services Check List ........................................................................... 4-9

4.8 SAFETY AND HEALTH TRAINING ................................................................................. 4-10


4-ii March 2009



March 2009 4-1

4 OCCUPATIONAL SAFETY AND HEALTH MANAGEMENT SYSTEM

4.1 SAFETY AND HEALTH a) Introduction In today’s business environment, safety is recognized as an obligation of the business owner or manager from a moral, ethical, legal and financial standpoint. The Occupational Safety and Health Management System (OSHMS) manual has been written to assist the manager in meeting these obligations. All managers, if asked, would state that they are in favor of plant safety. However, the prevention of accidents and illnesses is demanding responsibility. The Law of Malaysia, Occupational Safety and Health Act (OSHA) - Act 514 was enacted in 1994 in order to provide improved on-the job safety and health conditions for working man and woman in the nation. This manual is a guide for the Organization to plan the OSHMS for their workplace. The objectives of the manual are; i) To secure the safety, health and welfare of persons at work against risks to safety or health arising

out of the activities of persons at work. ii) To protect persons at a place of work other than person at work against risks to safety or health

arising out of the activities of persons at work. iii) To promote an occupational environment for persons at work which is adapted to their

physiological and psychological needs. iv) To provide the means whereby the associated occupational safety and health legislations and

approved industry codes of practice are operating together in order to maintain or improve the standards of safety and health.

Through this manual, its will help the organization to consider safety, health and welfare condition on workplace and to learn about possible solutions to the problems encountered. Please also refer to the latest version of the DID Departmental Policy Statements on Safety And Health, State JKKP (JawatanKuasa Keselamatan & Kesihatan Perkerjaan) and Mechanical Division JKKP statements for cross reference. b) Responsibility of employer and manager It shall be the duty of every employer and manager to ensure, so far as is practicable, the safety, health and welfare at work of all his employees. The matters to which the duty extends include in particular: i) the provision and maintenance of plant and system of work that are, so far as is practicable, safe

and without risk to health; ii) the making of arrangement for ensuring , so far as is practicable, safety and absence of risks to

health in connection with the use or operation, handling, storage and transport of plant ad substances;

iii) the provision of such information, instruction, training and supervision as is necessary to ensure, so far as is practicable, the safety and health at work of his employees;

iv) so far as is practicable, as regards to any place of work under the control of the employer, the maintenance of the means of access to and egress from it that are safe and without such risks;


4-2 March 2009

v) the provision and maintenance of a working environment for his employees that is, so far as is

practicable, safe, without risk to health, and with adequate as regards facilities for their welfare at work

It shall be the duty of every employer to prepare and as often as may be appropriate revise a written statement of his general policy with respect to the safety and health at work of his employees and the organization and arrangements for carrying out that policy, and to bring the statement and any revision of it to the notice of all of his employees. 4.2 GENERAL SAFETY AND HEALTH AWARENESS AND REQUIREMENT a) Promotion If safety is not continually promoted, the level of safety performance will decline. Early warning signs may be an increase of first aid injuries, a general increase in all or specific types of accidents, an increase in near miss incidents, or even housekeeping problems. These indicators will reflect that the system needs attention or promotion. When you attempt to discover the causes for an unfavorable safety performance trend and do not find specific factors, such as, training deficiencies, process changes, increased production schedules, or an influx of new personnel, you may find that the program needs additional promotion. Safety promotion can be achieved through a direct or indirect approach promotion or through a combination of both. Direct promotion approach Direct safety promotion involves direct intervention into the system, such as: • Modification of safety training programs, including retraining. • Provide short safety talks either at the start of each shift, following lunch, or during coffee

breaks. • Holding safety meeting led by line manager or the top executive officer in the facility explaining

management’s concern over declining safety performance. • Development of a safety information program. Such programs often include the posting of

accident-free work hours. This method utilizes bulletin boards, recording the number of hours worked since the last reportable accident or the number of hours worked since the last lost-time accident. Display safety posters pertinent to plant safety problems or place warning signs that an accident took place and the date of the accident.

• Evaluating safety performance on a regular basis. This can be accomplished by supervisor and line managers making routine evaluations of job performance. This type of promotion requires instant feedback on how well each individual is performing their assigned tasks. If they are doing everything correctly they should be complimented by the evaluator at the time of the observation or informed of what they are doing incorrectly.

A positive approach should be used for whatever means of direct safety promotion is selected. If you must point out that an individual is not performing a task safely you may want to take a tactful approach. If you use safety meetings to promote the improvement of safety performance, approach the subject by referring to a specific time when the safety performance was at an acceptable level. Do not set an improvement goal that is unrealistic attainable in a reasonable period of time. Once you have reversed the unfavorable performance trend and have reached the first goal, you may want to set the higher performance goals. Remember, you are trying to improve performance, not reach a zero accident level in one step.


March 2009 4-3

Indirect promotion approach An indirect promotion approach is one in which you use a secondary means to influence the behavior of the primary concern. The use of contest to improve safety performance is an example. The safety contest has become widely used means of promoting safety throughout industry. There are pros and cons concerning the use of safety contest to promote safety. Many companies have used a variety of safety contest as part of their on-going safety program. The premise for using a contest to stimulate safe work performance is that employees will enjoy competing for the recognition or prize and that the competitive drive will favorable influence safety performance. Safety contests have proven to be very successful in many major corporations and have been part of their ongoing safety systems for years. Others companies have used safety contests as a kickoff for a new safety effort or commitment, while some have been successful in using safety contests as a quick-fix for turning around unfavorable safety performance levels. b) Safety organization and management This topic is intended to remind management at a more senior level of organization they need to lay and to achieve a safe and healthy site. It will also, however, inform workers and supervisors of the necessity of a proper safety management system. The improvement of safety, health and working conditions depends ultimately upon people working together, whether employers or workers. Safety management involves the functions of planning, identifying problems areas, coordinating, controlling and directing the safety activities at the work site, all aimed at the prevention of accidents and ill health. Accident prevention is often misunderstood, for most people believe wrongly that the word “accident” is synonymous with “injury”. This assumes that no accident is of importance unless it results in an injury. Managers are obviously concerned with injuries to the workers, but their prime concern should be with the dangerous conditions causing the injury – with the “incident” rather than the “injury”. On a work site there are many more “incidents” than injuries. A dangerous act can be repeated hundreds of times before it results in an injury, and it is to eliminate these potential dangers that managers’ efforts must be directed. They cannot afford to wait for human or material damage before doing anything. So, safety management means applying safety measures before accidents happen. Effective safety management has three main objectives: - to make the environment safe; - to make the job safe; - to make workers safety conscious. c) Personal Protective Equipment (PPE) The working conditions in work site are in most cases such that , despite all preventive measures in project planning and work design, some personal protective equipment (PPE), such as a helmet, hearing and eye protection, boots and gloves, is needed to protect workers. Wherever possible, it is better to try to eliminate the hazard rather than providing PPE to guard against it. Some PPE such as safety helmets and footwear should be used on all work sites. The need for other PPE will depend on the sort of work being handled. Remember too, that proper work clothes will provide protection for the skin.


4-4 March 2009

On construction site there are often tasks where harmful dust, mist or gas may be present. Whenever there is doubt about the presence of toxic gases in the atmosphere, a respirator must be worn. The correct type of respirator will depend upon the hazard and the work conditions. Advice on suitable types of respirator and filter should be sought from appropriate safety and health authorities. The simplest masks are disposable paper types. Remember that these are only effective against nuisance dusts. The majority of fatal accidents in construction are due to falls from heights. Where work cannot be done from a scaffold or ladder, or from a mobile access platform, the wearing of safety harness may be the only way to prevent serious injury or death. A full safety harness should always be used in preference to a safety belt. A safety harness and its lanyard must: - Not permit a fall over 2m. - Be capable of supporting a workman’s weight. - Be attached to a strong structure through a firm anchorage point above the point of operation d. Welfare facilities Work in the work site is hazardous, it involves much manual or physical activity. It is also hazardous and dirty. Good welfare facilities not only improve workers’ welfare but also enhance efficiency. Welfare facilities such as the provision of drinking-water, washing, sanitary and changing accommodation, rest-rooms and shelter, facilities for preparing and eating meals, temporary housing, all help to reduce fatigue and improve workers’ health. 4.3 OCCUPATIONAL SAFETY AND HEALTH ACT a) Safety and health policy It shall be the duty of every employer to prepare and as often as may be appropriate to revise a written statement of the general policy with respect to the safety and health at work of his employees and the organization and arrangements for carrying out that policy, and to bring the statement and any revision of it to the notice of all of the employees. b) General duties of employees at work It shall be the duties of employees at work: i) to take reasonable care for the safety and health of himself and of other person who may be

affected by his acts or omission at work; ii) to co-operate with his employer or any other person in the discharge of any duty or requirement

imposed on the employer or that other person by this Act or any regulation made thereunder; iii) to wear or use at all times any protective equipment or clothing provided by the employer for the

purpose of preventing risks to his safety and health; iv) to comply with any instruction or measure on occupational safety and health instituted by his

employer or any other person by or under this Act or any regulation made thereunder.


March 2009 4-5

c) Safety and health officer An employer of a place of work shall employ a competent person to act as a safety and health officer at the place of work. The safety and health officer shall be employed exclusively for the purpose of ensuring the due observance at the place of work of the provisions of this Act and any regulation made thereunder and the promotion of a safe conduct of work at the place of work. d) Safety and health committee Every employer shall establish a safety and health committee at the place of work if there are forty or more persons employed at the place of work. Every employer shall consult the safety and health committee with a view to the making and maintenance of arrangements which will enable him and his employees to co-operate effectively in promoting and developing measures to ensure the safety and health at the place of work of the employees, and in checking the effectiveness of such measures. 4.3.1 Occupational Safety and Health Check List a) Statement of Safety and Health Policy i) No statement of Safety and Health Policy ii) Safety & Health Policy is written iii) There is a system to review regularly Safety & Health Policy b) Assignment of safety and health responsibilities and accountability. i) Responsibilities and accountability not assigned ii) A general understanding of safety and health responsibilities and accountability, but not written. iii) Responsibilities and accountability are emphasized in supervisor performance evaluations. c) Safety and Health Organization i) No safety organization in the organizational structure. ii) There is person-in-charge of safety and health or safety department established. iii) Safety and Health Department or safety officer reports direct to the top management iv) Auditing is carried out. d) Safety and Health Committee (If workers < 40 not applicable) i) No safety and health committee or have safety and health committee but inactive. ii) Composition of safety and health committee is from the management and workers iii) The safety committee meets as and when necessary iv) Minutes of meetings are maintained v) The safety committee is chaired by senior manager who is able to make decision on safety

matters


4-6 March 2009

4.4 ELECTRICITY SUPPLY ACT a) Registration of installations Before the completion of a new installation, the owner thereof shall forward to the Energy Commission an application for registration. The Commission shall cause inspection and test to be made, if the installation satisfies the requirements of this Act, shall issue a Certificate of Registration. b) Competent control Installation or electrical plant equipment shall be worked or operated by or under the direct supervision of the persons possessing the appropriate qualifications or holding a certificate of competency. c) Notification of accident Whenever any accident or fire causing or resulting in loss of life or hurt to any person or serious damage to property has occurred in connection with any installation or electrical plant or equipment, the owner thereof shall report the accident or fire to the Commission by the quickest means available. 4.5 ELECTRICITY REGULATIONS a) Supervision and test of installation Any electrical wiring in an installation which receives single phase supply, shall be under the immediate supervision of a Wireman with Single Phase Restriction or Three Phase Restriction, and upon completion of the installation, the Wireman shall certify a Supervision and Completion Certificate. Any electrical wiring in an installation operating at low voltage which receives three phase supply , shall be under the immediate supervision of a Wireman with Three Phase Restriction, and upon completion of the installation, the Wireman shall certify a Supervision and Completion Certificate. b) Material, equipment and method of installation Any apparatus, conductor or accessory for the purpose of connection to an installation shall be sufficient in size, power and number to serve the purpose for which it is intended and shall be constructed, installed, arranged, protected, worked and maintained in such a manner as to prevent danger. Any conductor or apparatus that is exposed to the weather, water, corrosion, undue heating or used in inflammable surrounding or in an explosive atmosphere shall be constructed or protected in such a manner as to prevent danger. c) General requirement of installation Any part of an installation where the switchboard or equipment is installed in any premises: i) shall be adequately lighted, ventilated and kept dry ii) shall be free from obstruction to facilitate the safe working of the switchboard or equipment iii) shall be ample sized to facilitate ample space for safe operation or maintenance iv) shall not be used for storage of any kind


March 2009 4-7

4.6 REGISTRATION OF ENGINEERS ACT a) Submitting plans or drawings -Only registered Professional Engineer may submit plans or drawings – No other person other than a registered Professional Engineer who is residing in Malaysia, shall be entitled to submit plans, drawings, schemes, proposals, reports, designs or studies to any person or authority in Malaysia b) Relation to the branch of engineering -Only registered Professional Engineer in relation to the branch of engineering in which the registered Professional Engineer is qualified may submit plans or drawings – The right of a registered Professional Engineer to submit plans, drawings, schemes, proposals, reports, designs or studies to any person or authority in Malaysia is subject to any restrictions imposed by the Board of Engineers and is restricted to the right to submit such documents only in relation to the branch of engineering in which the registered Professional Engineer is qualified as shown by the entries made in the register. c) Responsibility -Responsibility to employer, client or profession –

A Registered Engineer in his responsibility to his employer, client or profession shall have full regard to the public interest. 4.7 UNIFORM BUILDING BY – LAWS, FACTORY & MACHINERY ACT, FIRE SERVICES REQUIREMENTS 4.7.1 Firefighting System Safety Checklist a) Fire Detection System i) No system is provided at the plant or if there is any, there is no evidence that the system is

working. ii) There is evidence that the system provided complies with the minimum fire standard or

regulation iii) Maintenance and inspection on the system is just for compliance to the standard / regulation. iv) The system is maintained, tested and inspected regularly by the maintenance team. v) Effectiveness of the system is assessed and reviewed by expert from time to time especially

whenever there is a change in the plant layout or process. b) Fire Fighting Equipment i) No equipment is provided or if provided there is no evidence that it is in good working condition. ii) Evidence show that the equipment for firefighting is adequate as required by the fire standard /

regulation. iii) Maintenance / inspection are carried out just for the purpose of complying to the standard /

regulation. iv) The equipment is periodically checked by a competent person or trained personnel. v) All records of maintenance, test and inspection are kept safely for future reference.


4-8 March 2009

vi) The effectiveness of the equipment in term of number, type, location, etc are regularly reviewed

and assessed by expert, especially whenever there is a change in the plant layout or change in the process.

c) Fire Drill i) Drill has ever been conducted at the plant. ii) The drill is conducted regularly. iii) During the drill a designated person is controlling the exercise. iv) All workers assemble at a designated assembly area and head count is carried out. v) Effectiveness of the drill is evaluated and changes are made to overcome weakness. vi) Auditing is being carried out by external experts. 4.7.2 Machinery Safety Check List a) Machine Guarding i) Partial but inadequate or ineffective attempts at control are in evidence. ii) There is adequate control which meets applicable regulatory requirements but improvements

may still be made. iii) Steps are taken to minimize human errors and abuse. iv) Guards are integral in the machine design. Safety of operation is given prime consideration

during procurement or design. b) Maintenance of Machinery, Guards And Tools i) No systematic programme for maintaining machinery, guards, hand tools, controls and other

safety features of machinery. ii) Machine is maintained when breakdown occurs. iii) There is evidence of partial but inadequate or ineffective maintenance. Preventive maintenance

programme is partially practiced. iv) Preventive period maintenance programme for machinery, safety devices and tools is adequate.

Adequate maintenance is in evidence. v) A predictive or on-line maintenance system is programmed for hazardous equipment and

devices. vi) Safety reports are filed and safety department consulted when abnormal conditions are found. c) Hand Tools and Portable Power Tools i) Use of tools which are in poor condition eg. screw drivers with broken handles. ii) Using the wrong tools for the job e.g. pliers instead of wrenches. Incorrect use of tools e.g.

fitting a pipe as a lever to the handle of a wrench or spanner. iii) Tools in good condition and used properly. iv) All hand tools and power tools are repaired and maintained adequately so that no worn out tools

are used. v) Tool handles are of smooth finish, easy to grapes and without sharp edges or corners. vi) Tools of appropriate size and shape are chosen for easy and safe use. vii) Varying physical size of operators and shapes are taken into account when buying these tools


March 2009 4-9

4.7.3 Building Services Check List a) Housekeeping and Physical Arrangement i) Housekeeping, arrangement are generally poor, raw materials, items being processed & finished

materials are poorly stored, workplace untidy and workplace not adequate e,g. slippery or defective floors and surfaces.

ii) Housekeeping and arrangement are fair. Some attempts to orderly store materials and keep workplace tidy are being made.

iii) Adequate work-space is provided for operations as well as maintenance. iv) Housekeeping, arrangements and storage of materials are orderly. v) Incompatible items and processes are segregated. vi) Heavy and bulky objects are properly stored out of aisles. vii) Safe access and egress from workplace is provided viii) Housekeeping and storage of materials are well control ix) Layout and arrangement of facilities are systematic, properly segregated, tidy and very well

maintained. x) Switches, controls and materials which are frequently used are within easy reach and within the

working envelope of workers, workplace allows a comfortable posture and freedom of movement b) Seating Facilities i) No chair is provided where necessary. Workers have to stand while doing their work. ii) Chairs or benches of the correct height are made available. Footrests are also provided. iii) Chairs or benches provided are of adjustable type iv) Seat surface and cushion are suitable chosen for comfort v) Back rest of proper size which provides lower back support is included. vi) Where appropriate the operator is able to stand without interference vii) All staff are trained to sit correctly viii) Ergonomic factors are taken into considerations when buying chairs. c) Control and Displays i) All controls or displays are not easily accessible, visible and distinguishable from all relevant

working positions. ii) Most controls and display are easily accessible, visible and distinguishable to the workers or

operators. iii) Displays provided essential information about faults and emergencies. Controls are easy to use.

Related controls and displays are suitably arranged in a good operational sequence. iv) Suitable controls and display are designed and used according to ergonomic principle, with

proper symbol and labels. v) When purchasing new equipment or facilities the suitability of controls and display are taken into

consideration with respect to differences in physical size of operators


4-10 March 2009

d) Lighting i) All parts of working space or area are not adequately lit in accordance with recommended code

of practice. ii) Working area, spaces and corridors are adequately illuminated with the lighting fittings properly

places in relation to the work to minimize unwanted reflection iii) Illumination level is properly designed and determined. iv) Different task are provided with most appropriate level of illumination v) Task requiring special illumination is provided with screen or luminous background to make them

easy to see. vi) Available natural lighting is utilized to the best advantage. vii) There is no erect or reflected glare on working surface with lighting fitting readily accessible for

routine maintenance viii) Routine maintenance is regularly carried out. ix) Suitable finishes are used on the walls, roof and other main interior surface. The Factory & Machinery & Acts states the types of qualified personnel to operate certain machinery such as diesel engines. The Building By-laws states the requirements for fire protection against occupants, such as fire-fighting equipment and system, fire-proof door, fire-escape, etc. 4.8 SAFETY AND HEALTH TRAINING a) Introduction Many standards promulgated by OSHMS require the employer to train employees in the safety and health aspects of their jobs. Training is an essential part of every employer’s program for providing workers with a safe and healthy workplace. Many researchers conclude that those who are new on the job have a higher rate of accidents and injuries than those experienced workers. If ignorance of specific job hazards and of proper work practices is partly to blame for higher injury rates, then the training may help provide a solution. b) Recommended Training In addition to training currently required by OSH Act and Regulations, there are several other topics which management should consider integrating into the training program. These include: - Ergonomics - Heat and Cold Stress - Non-Ionizing Radiation - Environmental Rules and Regulations - First Aid - General Occupational Safety and Health Training


March 2009 4-11

c) The training process In order to maximize the effectiveness of any training program, the training process showed covers the following: - Identify training needs - Identify goals and objectives - Develop the training material - Conduct the training - Evaluate training effectiveness d) Recordkeeping It is recommended that sign-in log shall be documented as record keeping for each training course being conducted. It is also recommended that the course syllabus or schedule and any paper exercises be retained for the records. These can be important when the employees tell the inspector that he or she does not remember having taken the training in question.


4-12 March 2009


CHAPTER 5 PLANT MANAGEMENT AND CONTROL

Chapter 5 PLANT MANAGEMENT AND CONTROL

March 2009 5-i

Table of Contents


List of Figures ................................................................................................................... 5-ii

5.1 INTRODUCTION .......................................................................................................... 5-1

5.1.1 The main objectives of plant management and control are:- ............................. 5-1

5.1.2 Failure to establish proper plant management and control will result in:- ........... 5-1

5.1.3 Important factors for proper plant management and control ............................ 5-1

5.2 MANAGEMENT AND CONTROL OF PLANTS. .................................................................... 5-1

5.2.1 Plant records ................................................................................................ 5-1

5.2.2 Plant technical literature and data .................................................................. 5-3

5.2.3 Workshop and store facilities ......................................................................... 5-3

5.2.4 Maintenance control ...................................................................................... 5-4

5.2.5 Reports ........................................................................................................ 5-4

5.3 MANAGEMENT AND CONTROL OF PERSONNEL .............................................................. 5-4

5.3.1 Maintenance personnel .................................................................................. 5-4

5.4 SUMMARY ................................................................................................................... 5-6

APPENDIX 5A PLANT REGISTER ........................................................................................ 5A-1

APPENDIX 5B1 PLANT MOVEMENT RECORD ....................................................................... 5A-2

APPENDIX 5B2 PLANT MOVEMENT RECORD ........................................................................ 5A-3

APPENDIX 5C ANNUALl RETURN ANALYSIS ........................................................................ 5A-4

APPENDIX 5D MONTHLY RETURN ..................................................................................... 5A-5

APPENDIX 5E DAILY RUNNING RECORDS .......................................................................... 5A-6

APPENDIX 5F WRITE-OFF REPORT ................................................................................... 5A-7

APPENDIX 5G STANDING ORDERS FOR PLANT OPERATORS ............................................... 5A-9

APPENDIX 5H MAINTENANCE AND OVERHAUL PROGRAM ................................................. 5A-11

APPENDIX 5I PLANT MAINTENANCE AND CONTROL CHART ............................................. 5A-14


5-ii March 2009

List of Figures

Figure

Description Page

5.1

5.2

Mechanical Plan Records

Maintenance Personnel Chart

5-2

5-5


March 2009 5-1

5 PLANT MANAGEMENT AND CONTROL

5.1 INTRODUCTION Mechanical plants are used in almost all development and maintenance projects. In a small organization, less mechanical plants are employed and the problems associated with these plants are less complicated and easier to manage. In a large organization like DID, which owns a large fleet of various types of mechanical plants (Pump Sets, Gates, Earth-moving Plants, Vehicles, etc), the problems encountered are more complicated and therefore a more organized type of management and control is necessary to ensure smooth and successful implementation of projects. 5.1.1 The main objectives of plant management and control are:- a) Maximum plant utilization- to cut down non – productive time such as idling time and

breakdown. b) Higher plant efficiency – good plant performance at low operational cost. c) Reduce maintenance cost – maintenance cost due to breakdown and during overhaul. d) Prolong useful and economical life of plants – to save capital costs for replacement of plants. 5.1.2 Failure to establish proper plant management and control will result in:-

a) High project cost – capital costs, operational costs and maintenance costs. b) Delay in projects. 5.1.3 Important factors for proper plant management and control The important factors to be considered for the proper plant management and control are discussed under two headings:- a) Management and control of plants b) Management and control of personnel. 5.2 MANAGEMENT AND CONTROL OF PLANTS. 5.2.1 Plant records These are essential for any future reference, types of records include:- a) Plant register (Appendix 5A) – Which records the history of the plant from the time it was

purchased until it is written off. It records:-

i) Technical details of the plant ii) Maintenance repair costs iii) Plant Movements or transfers iv) General remarks such as modification to its design, etc.

b) Plant Movement record (Appendices 5B1 & 5B2) – to report movement of plant from one place to another. i) PIAN (Plant Inward Advice Note) – used when receiving incoming plants. ii) POAN (Plant Outward Advice Note) – used when sending plants to other places.


5-2 March 2009

c) Annual Return Analysis (Appendix 5C) – to report to the central recording centre on the annual operation and maintenance cost of running of the plant. d) Monthly Return (Appendix 5D) – to report to the central recording centre on the monthly operation and maintenance cost of running of the plant. Thus annual returns re-compiled from the monthly returns. e) Daily Running Records or Log Sheets. (Appendix 5E) – to record the activity, output and cost of running of the plant daily. Form these records, monthly returns could be prepared. (The records are normally kept with the plants). f) Write – Off Report or BER (Beyond Economical Repair) Report (Appendix 5F) – to report and recommend that the plant is beyond economical repair and usage, and its life expectancy is over. g) Other record from time to time:- e.g.(i) Delivery Notes – During the delivery of new plants by the supplier. (ii) Maintenance record- during overhaul where there are major replacements of important and expensive parts or when plant had been modified. To give a summary of the various types of records mentioned above a flow chart is given below to show their inter-relationship.

Delivery Notes

Technical Details

Fig. 5.1 Mechanical Plan Records


March 2009 5-3

5.2.2 Plant technical literature and data Essential for the proper operation and maintenance of plants. a) Technical Literature – to provide technical details regarding the plant construction, application, limitation and life expectancy (if any). b) Operation and Maintenance Manual – provided by the plant manufacturer to assist in the operation and maintenance personnel on the proper procedures and precautions to be taken during operation and the proper maintenance procedures to service, repair and overhaul of the plant. c) Departmental Manual – compiled by the department through previous records and experience, to provide standard procedures and practices for operation and maintenance of existing plants. These procedure and practices need to be reviewed from time to time. 5.2.3 Workshop and store facilities Essential to provide supporting services in order that operation and maintenance of plants may be carried out smoothly and readily. a) Workshop facilities – in general, to provide a proper and clean working place for the maintenance personnel to repair and overhaul the plant with proper tools and equipment. In DID Malaysia, the idea of a Three Shop System is used so that different types of maintenance work may be distributed and carried out at three different types of workshops to ensure effectiveness and economy of maintenance. i) Federal workshop – to do more specialised work such as general overhaul of big plants, modification work and training of all personnel. ii) State Workshop- to do overhaul of smaller plants, major repair and monitoring of preventive maintenance programmes, inspection of plants and training of field personnel. iii) District Workshop – to do minor repair works and preventive maintenance of plants (i.e. routine servicing). The Three Shop System is applicable when the numbers of plants are large and they are widely distributed throughout the country. b) Store Facilities - to procure and to provide a proper and safe storage place for keeping spare parts, fuel, lubricants etc. for uninterrupted essentials for the plants. Proper record and documentation are required for any store to carry out its main functions: Purchase, receipt, storage and issue of materials. Similar to the workshop classification, stores could also be placed into three categories in order to facilitate smooth supply of materials: i) Federal Store ii) State Store iii) District Store Spare part catalogues are useful for the order of spare parts for plants. The catalogues may be obtained from the supplier of the plants.


5-4 March 2009

5.2.4 Maintenance control It is important to ensure that plants and equipments in the field to performance efficiently and economically throughout. It involves timely parts replacement and repairs to the machine to ensure economically high machine availability. a) Lubrication and Maintenance Charts – Form the basis for any maintenance schedule so that the field fitters can carry out maintenance accordingly. b) Maintenance Programme - Guide the field fitters in carrying out maintenance /servicing. c) Inspection Programme – Regular inspection shall be carried out by chargeman or trained Technical Assistant/ Technician with proper inspection report. d) Technical Analysis – Annual assessment on condition and plant performance is necessary so that any major repair can be planned and impending components failure can be avoided. Special tools and instruments can help to pinpoint the exact trouble with the machine. e) Machine Repair Record – Keep track of the components which have been replaced, service and parts cost, downtime experienced etc. Also, planning component replacement before required and hence a less costly repair. 5.2.5 Reports Information on plant shall be readily made available to management for either operational control or budgetary control. Reports as listed below are required:- a) Plant Location Update b) Plant Utilisation Report c) Maintenance Cost Breakdown d) Plant Cost Analysis e) Analysis of Purchases and Disposals. 5.3 MANAGEMENT AND CONTROL OF PERSONNEL Operational personnel - include plants operators, supervisors for the plant operators, and transport personnel (vehicle drivers) The following factors will affect the performance of the operational personnel. a) Duty List – proper duty list shall be given to all personnel so that they are aware of their duties (see lecture notes on gates) b) Duty Roster - given to personnel to show when and where to work and what type of work is to be carried out. c) Standing Orders for plants operators - This is an extract from the Technical Literature and data available, put in a simple and straight forward manner, so that operators can operate (start, stop, record) and do the necessary checking and maintenance (Appendix 5G). d) Safety precaution is included to prevent accident which might cause serious injury or death to the operators. e) Training of operational personnel - to provide: i) Initial training before handing over of plant to the operators. ii) Training on operation and maintenance to improve overall performance of plants. 5.3.1 Maintenance personnel Maintenance personnel comprises of workshop supervisors and mechanics to provide proper maintenance, procedures and practices to ensure minimum breakdown and idle time.


March 2009 5-5

Factors to consider:- a) Duty List - See section 3.1 (a) b) Duty Roster - See Section 3.1 (b) c) Maintenance and overhaul programme - to be given or prepared by the maintenance supervisor so that maintenance can be carried put according to Maintenance Schedule (Appendix 5H) of the Plant. d) Training of maintenance personnel - to improve and update their skill and knowledge so that repair and maintenance can be carried out more efficiently and effectively. e) Inspection report - Normally carried out at regular intervals (annually or half-annually) on the plants which help to formulate the future maintenance and overhaul programme. The management and control of operation and maintenance personnel is by one person who is normally the engineer in charge. A typical organization chart for the management and control of personnel is as shown below:-

Fig. 5.2 Maintenance Personnel Chart


5-6 March 2009

5.4 SUMMARY As a summary, an Engineer or Technical Manager of plants in an organization should have the following knowledge, in order to carry out plant management and control properly. a) Familiar with the various types of plants records and their usage. b) Aware and acquire various types of Plants Technical Literatures and Data useful for future use. c) Able to provide the necessary workshop and store facilities required to carry out operation and maintenance works. d) Familiar with the types of operational and maintenance personnel’s required for various plants. e) Aware of the necessity to provide training to the operational and maintenance personnel to improve their performance and skill. f) Appreciate the importance of maintenance (checking, lubrication, preventive maintenance and inspection) for plants. As a conclusion the Plant Maintenance and Control Chart (Appendix 5I) shall be a useful guide for Engineers in charge of the mechanical and electrical plants and equipment.


March 2009 5A-1

APPENDIX 5A PLANT REGISTER

AP

PEN

DIX

5A


5A-2 March 2009

APPENDIX 5B1 PLANT MOVEMENT RECORD

APPENDIX 5B1


March 2009 5A-3

APPENDIX 5B2 PLANT MOVEMENT RECORD

APPENDIX 5B2


5A-4 March 2009

APPENDIX 5C ANNUAL RETURN ANALYSIS

A

PP

END

IX 5

C


March 2009 5A-5

APPENDIX 5D MONTHLY RETURN

AP

PEN

DIX

5D


5A-6 March 2009

APPENDIX 5E DAILY RUNNING RECORDS

AP

PEN

DIX

5E


March 2009 5A-7

APPENDIX 5F WRITE-OFF REPORT

GOVERMENT OF MALAYSIA CERTIFICATE PLANT BEYOND ECONOMICAL REPAIR

Plant make: Caterpillar U.S.A Year of Purchase: 1961 Plant Type: D7 Tractor Original Purchase: $57,770.00 Registration No. - Total Hours Run: 40,000 hours Engine No. 17A – 18672 Total Cost of Repair: $80,000.00 Chassis No. 17A – 18672 Price: $6,000.00 D.I.D. No. 56 Estimated Value After Repair: $86,000.00 Plant Sheet No. Plant Register No. 26 Estimated Useful life after repairs: 2 years Page 4 INSPECTION REPORT Details of Repairs Required: 1. TRACK FRAME: At all parts of the Track roller frame are entirely damaged and very rusty. All bolts and nuts jammed. Track plates, track link and master link has worn out very badly and need to be changed. Track roller, idler roller, top roller has worn out very badly and need to be changed. The sprocket teeth had also worn out and need to be changed. 2. TRANSMISSION AND CLUTCH: The flywheel clutch need to be overhaul and the clutch lining need to be changed, the final drive pinion is found cracked and the pinion Bearing is entirely damaged and need to be changed. The gear oil is leaking very badly, gear box need to be overhaul. The oil seal and bearing need to be changed. 3. DONKEY ENGINE: The condition of the engine is very bad and need major overhaul. 4. MAIN ENGINE: The condition of the engine is very bad and need major overhaul. Piston and other engine parts had to be changed. 5. HYDRAULIC SYSTEM: Hydraulic pump control valve leaking very badly. Hydraulic pump is entirely damage and all parts need to be changed. Rams and hydraulic hose is leaking and need to be changed. 6. GENERAL: All parts of electrical system is damaged. Wire, battery and output regulator had to be changed. Dynamo, starter motor need to be repaired and changed. U-frame need repair, cutting blade and cutting edge had worn out very badly and need to be changed. Certificated that Plants No. as mentioned has been examined and is beyond economical repair for the following reasons: 1. The machine is 22 years old, the machine has undergo 4 times of major overhaul. At all conditions the machine is entirely damaged very badly. If the machine needs repair, many new parts has to be used in which the cost of repair is very high and difficult to get the spares in the market this is to suggest that the machine need to be written-off. The machine need not to have a replacement because there is an extra machine that can still being used in the “Federal Pool”. t.t. Signature: Ketua Jurutera Jentera, Jabatan Parit dan Tabi Air, Worksyop Persekutuan, Ipoh.


5A-8 March 2009

Note: (1) This Certificate can only be issued by an authorized Mechanical Engineer appointed by Government. (2) The residual Value of a Plant to be estimated on straight line depreciation in accordance with the average economic life given in Appendix ‘A’ a minimum value of 10% of its purchase price. t.t. t.t. Prepared by J.J. LKT. Checked by: J.J.K. II


March 2009 5A-9

APPENIDX 5G STANDING ORDERS FOR PLANT OPERATORS

STANDING ORDERS FOR PUMP OPERATORS AND PUMP ATTENDANTS FOR ELECTRICALLY OPERATED PUMPHOUSE

All pump operators and attendants must fully understand and be conversant with these standing orders and other instructions issued from time to time. These orders must be strictly adhered to in order to safeguard the personnel and the equipment during operation. 1. Before Starting:- a) Check for any rubbish and logs collected in front of the trashscreen; remove if any. b) Check that the grease pump is adequately charged with grease; fill up with the coupling flange beneath the motor support. c) Ensure that the pump can be turned by hand by turning with one hand the coupling flange beneath the motor support. d) Ensure that the control knob on the control panel is in the “OFF” position before starting. e) Check voltage with the volt-meter. Each phase should read about 415 volts unless the supply voltage is higher. 2. To start Pump:- a) Turn isolating switch into “ON” position. Normally a red light will indicate that supply is on. b) If a grease pump is provide turn control knob into “Hand-grease Pump” position and allow grease pump to run for 5 minutes. Check that grease pump is working by turning the screw to ensure that grease is being pumped out. c) If a grease pump is provided then turn control knob into “Hand-Both Pumps” position to start the pump. d) Normally a green light indicates the motor is running and check the ammeter reading which will fall from starting current to normal running current in about 10 seconds. The values of the currents will be given by the manufacturers. e) Stop the pump immediately by turning the control knob to “OFF” position if the ammeter remains at a higher ampere reading. f) If the motor trips, note the ammeter reading when the motor trips and reports to the Officer-in-charge. Do not start the pump again. 3. While Pump is Running:- a) Keep regular checks on the ammeter to ensure that the reading does not exceed the allowed amperage. Stop the pump immediately if the reading is rising or higher than the allowed reading. b) Ensure all the time that the grease pump provided is working when the big pump is running. If the grease pump stops the big pump must be stopped immediately. c) Listen for any unusual noise from the motor, pump or control cubicles. 4. To Stop Pumps:- a) Stop pump by turning the control knob into “OFF” position. b) Never stop the pump by turning off the main isolation switch. c) Leave the heaters on if the pumps remain idle for a long time.


5A-10 March 2009

5. Maintenance:- a) Operators are not required to carry out maintenance of the motors and the control cubicles. This will be done by qualified personnel. b) Keep all equipment and the interior of the pump house free of all dust, dirt, grease and water. c) Grease the motor bearings through the greasing points with Shell Alvania No.3 after 1,000 hours or 3 months of running. d) Grease the tapper bearings of the pumps with grease pump once in 1,000 hours or 3 months of running. e) Check and top up the grease pump’s oil sump with oil to correct level monthly. 6. General:- a) The daily log sheet must be entered by the operator promptly during his shift. b) The pumps are to be operated by the appointed operators only. Unauthorized persons are not allowed inside the pump house. 7. Emergency:- a) Any breakdown of the equipment should be reported to the Officer-in-Charge. Do not attempt to repair the equipment. b) Failure of electricity supply should be reported to National Electricity Board immediately. c) For emergency stop use the trip in the Air Circuit Breaker to disconnect the electricity supply.


March 2009 5A-11

APPENDIX 5H MAINTENANCE AND OVERHAUL PROGRAM

1 MAINTENANCE SCHEDULE FOR MECHANICAL AND ELECTRICAL EQUIPMENT, SG. BURIONG TIDAL CONTROL GATE 1.1 Electrical Control Panel

No. Item Inspected 3-Monthly Yearly (a) Electrical contactor Service and clean contact

point

(b) Switchboard panel Visual check on damage (c) Flexible conduit Change flexible conduit if

damage (d) Electrical connections Check for loosen parts and

tighten it if necessary

(e) Junction box Check for leakage (f) Wiring Visual check for damage

All items above should be carried out by qualified electrician. 1.2 Roller Gate & Hoisting Equipment (i) Roller Gate Gate should be visually checked daily to ensure that the proper sitting of the gate seals. Excessive rubbish collected on the gates shall be removed.

No. Item Things to look for (a) Skin plates, top channel,

brackets Monthly inspection on damaged areas, weld cracks, broken bolts

(b) Seal Monthly inspection on damaged parts, loose or missing parts. (Note: replace seal if excessive leakage through the seal)

(c) Gate sill, guides and Main Roller track

Monthly inspection on damaged surface. All the debris and scaling over embedded parts should be removed.

(d) Main Roller Monthly inspection on damaged tread and loose parts. Ensure no rubbish stuck between roller and bracket. Rotate the roller a number of times to ensure its free rotation.

(e) Hoisting connections Monthly check on loose connection


5A-12 March 2009

(ii) Hoisting System The gear drive units shall be checked daily for oil leaks. When operating, check for unusual noise. Run at least 10 minutes each week while it is idle. Check the oil level before starting.

No. Item Things to look for (a) Electrical connections Monthly check on loose connection (b) Gearbox and actuator Monthly inspection on oil leaks.

(Note: replace oil every two years for SAE 90 EP) (c) Operator’s control Monthly check for proper operation (d) Wire rope Monthly inspection on broken strands and wear. (e) Shaft and coupling Monthly check on loose bolts and broken parts (f) Drum and sheaves Monthly check on groove wears. Lubricate if necessary (g) Actuator battery Monthly check on the battery level status (icon

display). Replace battery every 5 years Note: Detailed information on battery replacement and torque/position monitoring is contained in Chapter 10 of Rotork IQ Range Installation and Maintenance Instructions. 2 YEARLY OPERATION CHECK Proper schedule of testing is necessary to ensure the whole gate system continues to function well. 2.1 Gate Operate the gate through a complete cycle from fully closed to fully open then to fully closed, checking that the gate moves freely and smoothly. Tell-tale sign associated with the potential operating problems with the gates: • Jerking or rough operation • Leakage through sealing area • Vibration of the gate • Abnormal noise • Binding 2.2 Electrical System All electrical connections and electrical cables shall be visually inspected for external deformed, damage, and for indication of possible damages. Equipment found to be deformed or damaged shall be removed and investigation shall be carried out before being replaced. Check all equipment grounding conductors for proper connections. 2.3 Hoisting System (Actuator, Gearbox, Transmission Shaft, Rope-drum) Operate the gate from full open to close and vice versa, check that all parts function properly and operate smoothly, and that the control of all load during lowering is accurate and not jerky.


March 2009 5A-13

Tell-tale signs associated with potential operating problems: • Unusual noise • Look for binding or misalignment • Correct operation of the limit switches • Misalignment and wobbling of transmission shaft • Oil leaks NOTE Ensure that excessive force is not required while cranking the hand-wheel to operate the gate through the complete cycle. 3 LUBRICATION Recommended lubricant shall be as follows:

Items Description Recommended Lubricant Actuator / Gearbox Shell Spirax EP2 Greasing points (rope-drum) Shell Alvanis EP2 grease

4 SETTING AND ADJUSTMENT (ROTORK ACTUATOR) Primary Functions - Setting for end of travel limit actions, torque values, limit positions, etc. Secondary Functions - Settings covering the control, indications and optional equipment functions. Refer to Chapter 7, 8 & 9 of Rotork IQ Range, Installation & Maintenance Instructions (Publication Number E170E2 for setting procedure.


5A-14 March 2009

APPENDIX 5I PLANT MAINTENANCE AND CONTROL CHART

AP

PEN

DIX

5I

CHAPTER 6 ENERGY EFFICIENCY IN MANAGEMENT OF M&E INSTALLATION

Chapter 6 ENERGY EFFICIENCY IN MANAGEMENT OF M&E INSTALLATION

March 2009 6-i

Table of Contents



6.1 ENERGY EFFICIENCY POLICY AND CONCEPT ................................................................. 6-1

6.2 SYSTEM DESIGN AND AUDIT ........................................................................................ 6-2

6.3 AUDIT CHECKLIST ....................................................................................................... 6-4

6.4 AUDIT REPORT ........................................................................................................... 6-5

6.5 IMPLEMENTATION OF IMPROVEMENT WORKS .............................................................. 6-6

6.6 SOLAR ........................................................................................................................ 6-7


6-ii March 2009

List of Figures

Figure

Description Page

6.1

6.2

Typical Solar Cell

Typical PV Powered Motorised Water Gate Control

6-8

6-9


March 2009 6-1

6 ENERGY EFFICIENCY IN MANAGEMENT OF M&E INSTALLATION

6.1 ENERGY EFFICIENCY POLICY AND CONCEPT Energy efficiency is a process of reducing or eliminating energy waste with the same level of productivity or services. In other word, it is how we manage effectively the usage of energy. In order to achieve energy efficiency, it requires a systematic and structured approach besides a logical and comprehensive management approach. It needs a disciplined activity covering all the steps to achieve energy efficiency as part of overall energy conservation programme. Steps to achieve energy efficiency are as showed below:- a) Energy audit b) Identification of energy saving measures c) Implementation of energy saving measures d) Evaluation of measures In order to have effective results on Electricity Energy Efficiency regulation we need to address on the energy management programme. It is the establishment of a successful energy management programme for an industrial facility which depend upon the full interest and encouragement of top management of the facility as well as a formulated department policy committed in the effort to reduce energy consumption resulting in operational cost savings. Supervision of the energy management program must be delegated to those members of the staff within the organization who will commit the time and resources necessary. The program will not be successful if it is assigned as a part- time duty to staff members whose prime responsibilities lie in other area. In some instances, sufficient in-house staff may be available to develop a program; however, the management of many industrial facilities will not have access to a staff sufficiently conversant with such a program. If additional services are needed, they may be obtained through the use of consultant and engineering firms specializing in energy management technology. In order to ensure the success of a program, periodic report should be provided to management. Report showing benefits achieved, resources required, manpower and capital should be included. The report should be reviewed and commented upon by top management. Full commitment from all levels of the organisation is required if the program is to be successful. The energy management processes are:- a) Obtain management approval and commitment Key to success in an engineering effort is the approval and involvement of top management and supervision. The approval is even more important in energy management program because expenditures will generally have no effect on production output. However, long-term major cost reductions can often be realized. b) Embarking from energy management program It is important to establish the existing pattern of electricity usage and to identify area where energy consumption could be reduced. A history of electric usage, on a month-by-month basic, is available from electric bills; this usage should be carefully recorded in format that will facilitate future reference, evaluation and analysis. Items to be recorded for evaluation and analysis shall include:-


6-2 March 2009

- Billing monthReading time - Days in billing cycle - Kilowatt hours - Billing kilowatt demand - Actual kilowatt demand - Kilovars - Kilovar hours - Power factor - Power bill (broken down into the above categories plus fuel cost and any additional charge) - Production level - Additional column(s) for remarks (such as plant vacation periods) 6.2 SYSTEM DESIGN AND AUDIT The incorporation of energy efficiency management system during design stage has generally been ignored in the building development in Malaysia in the past. The main reason towards this is generally due to the initial cost, which is practically in the order of 5%-10% dearer than the traditional building design and construction cost. In principle, energy cost should be considered for the optimisation of all design projects. Any additional costs (due to energy efficiency features) of reviewing the project can be estimated at the start of the project. It would appear to be reasonable if these additional costs can be recovered within half a year in the form of energy savings, as allowances should also be made for any additional investment required. As a simple rule of thumb, if the estimated energy savings are expected to be 15% as a result of the added energy efficiency design, then the additional costs should correspond to a maximum of 7.5% of the expected annual energy costs. Strategically, the design of the energy efficiency building process focuses on the architectural design (building envelope) and passive design for the purpose of reducing the building heat load, use of daylight, natural ventilation, zoning, selection of efficient equipment including air-conditioning, lightning, office equipment and effective control system. Passive design refers to the design features of the building, which help to reduce the heat gains through the building envelope construction itself. Passive design also includes taking advantage of natural phenomena such as natural ventilation and use of daylight to partly substitute mechanical ventilation and artificial electrical lightning. Most importantly, proper building orientation plays the major role in the passive design features. The placement and orientation of the building should be such that its long facades with majority of windows and main entrance shall not face the east and west. Further, the shape of the building should be such that the building envelope heat gain is minimized, such as, building with minimum possible of wall to floor area ratio. Choice of window size and its glass type will further enhance another important element in passive design by utilizing the daylight. Window with bigger size allows the daylight penetrates into the building, however it may also allow the solar heat gain through radiation. Therefore, proper shading of the building and windows should be optimized to avoid direct sunlight, and at the same time maximize diffused light into the building by proper depth of overhangs and reveal.


March 2009 6-3

It is equally important to consider glass window with low-emittance (Low-E Glass), which can reduce solar heat gain up to 80%. The setback of this type of glass is that it reduces the amount of natural daylight diffuse into the building. Alternatively, a few of advanced technology glazing systems is said to be the next best solution to these problem, whereby it has some acceptable range of shading coefficient (which block certain solar rays that contain heat) and also acceptable transmission to daylight. Insulation at the roof and wall is another important feature to reduce the heat gain into the building, especially in a tropical climate like Malaysia. Insulation increases the resistance of a structure to heat flow. For example, roof insulated with extruded polystyrene form on the flat roof and wall with aerated concrete will remarkably reduce the solar heat gain compared to the normal single roof and brick wall. Planning the usage of space or zoning in the building would give extra advantage to maximize the utilization of daylight in the building. Work, which requires less concentration on light requirement (meeting room, seminar room, ballroom, stores, etc) should be placed in the “Artificial Light Zone”, whereas work which requires high intensive of lighting such as office for workers and managers should be placed at the daylight zone. The designer of air conditioning systems for both new and existing buildings should have as a philosophy that systems, equipment and systems operation will be selected to minimize energy use. Some points that need to be considered in the selection of services for new and existing building are:- - Setting energy targets for air conditioning services based on owner cost expectations and

building services expected life. - Minimization of the energy use of all pieces of equipment through examination of equipment part

load and full load efficiencies and optimum operating conditions - Selecting fans and pumps with low input power to output capacity and using operational

strategies to keep energy usage as low as possible - Selecting systems and operational strategies that avoid the need for concurrent cooling and

heating (e.g. dehumidification cycles or reheat systems) - Operation of the minimum amount of plant to provide acceptable space conditions when use out

of normal work hours is necessary - Using separate systems to condition spaces, which have different hours for use (e.g. offices,

shops, computer rooms, PABX rooms, entrance lobbies and foyers) - Using outside air cycles where climate allows - Integration of outside air cycles with smoke control Energy efficiency imply to improve efficiency, all we need to do is to improve motors efficiency as operation of pump/motors accounts for 80% -90% of the energy costs in the water supply for irrigation and drainage. The life time energy costs to run a continuous- duty motor are 10-25 times higher than original motor purchase price. Thus energy efficient can play a major role in reducing facility operating costs. The potential of energy saving in a motor and drive could be achieved through improvements in the motor installation such as:- Correct sizing of motor and drive-set-up during the design stage Managing the process to remove unnecessary load Keeping idling time to minimum


6-4 March 2009

Organizing appropriate maintenance Improving power factor Use of high efficiency motor and variable speed drive

Energy reduction strategies for motor/pump and drives for the department have categories: a) IMPROVE POWER FACTOR The energy losses in electric motor can either be load dependent or load independent. Load dependent losses such as stator losses, winding losses rotor losses stray losses (mechanical losses). Load independent such as transmission losses. b) APPLICATION OF NEW TECHNOLOGIES Improve technologies such as Variable Speed Drive(VSD) High efficieny motor

6.3 AUDIT CHECKLIST As for energy audit, the objective is to study and understand the energy consumption pattern. It will examine where the incoming energy to a premise is being consumed and places where energy is lost. Besides, it is also to examine the condition of energy consuming equipment. It will identify any equipment which consumes more energy than what it should be. Based on the survey made, analysis will be made to identify energy efficiency improvement opportunities and to evaluate the implementation costs and savings obtained. Steps in energy audit should include:- a) Interview of facility personnel b) Facility tour c) Document review d) Utility analysis e) Measurement of energy consumption f) Identification of energy saving measures g) Economic analysis h) Report of findings Energy audit can be categorized into the followings:- a) Preliminary or walk through audit b) Detailed audit c) Investment grade audit The first is preliminary audit alternatively called a simple audit, screening audit or walk-through audit, which is the simplest and quickest type of audit. It involves minimal interviews with site operating personnel, a brief review of facility utility bills and other operating data, and a walk-through of the facility to become familiar with the building operation and identify glaring areas of energy waste or inefficiency. Typically, only major problem areas will be uncovered during this type of audit. Corrective measures are briefly described, and quick estimates of implementation cost, potential operating cost savings, and simple payback periods are provided. This level of detail, while not sufficient for reaching a final decision on implementing proposed measures, is adequate to prioritize energy efficiency projects and determine the need for a more detailed audit.


March 2009 6-5

Secondly is detailed audit, alternatively called a mini-audit, site energy audit or complete site energy audit which expands on the preliminary audit described above by collecting more detailed information about facility operation and performing a more detailed evaluation of energy conservation measures identified. Utility bills are collected for a 12 to 36 month period to allow the auditor to evaluate the facility's energy/demand rate structures, and energy usage profiles. Additional metering of specific energy-consuming systems is often performed to supplement utility data. In-depth interviews with facility operating personnel are conducted to provide a better understanding of major energy consuming systems as well as insight into variations in daily and annual energy consumption and demand. This type of audit will be able to identify all energy conservation measures appropriate for the facility given its operating parameters. A detailed financial analysis is performed for each measure based on detailed implementation cost estimates, site-specific operating cost savings, and the customer's investment criteria. Sufficient detail is provided to justify project implementation. Finally is investment grade audit. In most corporate settings, upgrades to a facility's energy infrastructure must compete with non-energy related investments for capital funding. Both energy and non-energy investments are rated on a single set of financial criteria that generally stress the expected return on investment (ROI). The projected operating savings from the implementation of energy projects must be developed such that they provide a high level of confidence. In fact, investors often demand guaranteed savings. The investment-grader audit alternatively called a comprehensive audit, detailed audit, maxi audit, or technical analysis audit, expands on the general audit described above by providing a dynamic model of energy use characteristics of both the existing facility and all energy conservation measures identified. The building model is calibrated against actual utility data to provide a realistic baseline against which to compute operating savings for proposed measures. Extensive attention is given to understanding not only the operating characteristics of all energy consuming systems, but also situations that cause load profile variations on both an annual and daily basis. Existing utility data is supplemented with submetering of major energy consuming systems and monitoring of system operating characteristics 6.4 AUDIT REPORT The audit report comprises of:- a) Desktop data collection-this study will be based on the information available in the hardcopy form such as the architecture drawings, mechanical and electrical documents, manual and also electricity bills. b) Field data collection- the Audit team will go to each of the buildings to gather the relevant data manually. c) Measurement- a number of data loggers is going to be installed at several locations for a certain period in order to establish the typical daily load curve of the buildings. d) Data analysis and apportioning-analysis is further by implementing on the captured data using readily available software specified by the consultant. The load of each building will be apportioned into three categories that include air- conditioning load, lighting load and general equipment load. e) Energy saving measures- Once the energy consumption of each building is evaluated; the consultant suggests several energy saving measures to be implemented on each building. Energy consumption pattern and some energy saving potentials can be employed in the building without disturbing the normal operation and activities of the buildings.


6-6 March 2009

6.5 IMPLEMENTATION OF IMPROVEMENT WORKS Any implementation of improvement work should be conducted with energy efficiency conscious in mind. There are a number of opportunities for making building more energy efficient which do not require the department to compromise other requirements, such as those regarding quality, lifetime, precision and efficiency. In energy conscious implementation, energy efficiency is included as an ‘extra’ requirement added to normal. It is obvious that selecting energy efficient equipment at the purchasing stage is more economical than buying the equipment afterwards, because the payback period will be considerably shorter than if the savings were made at a later date. Typically, technical purchasers experience a lot of difficulties in purchasing energy efficient equipment, because of the low priority given to this aspect by the management. This means that resources for those purchasers are seldom set aside in the budget either in the form of time to investigate the alternatives properly or in the form of money for any additional investment in equipment. This equipment is usually more expensive but they are cheaper in the longer time. Another obstacle facing energy conscious implementation is that replacements often have to be made on an emergency basis, i.e. sudden breakdown. This means that it is difficult to find time to investigate more energy efficient alternatives. Other obstacles include a lack of information about the technical possibilities, a lack of knowledge about energy matters on the part of the suppliers and problems of cooperation both internally in the department and externally with suppliers and consultants. Several of the department’s personnel are usually involved in the purchase of new equipment. In many cases the personnel actually involved depends on the type of equipment to be purchased. Department are organized differently and this naturally has an influence on which people are involved in the purchase. For this reason, the person to be responsible for the energy efficiency of new equipment and for the procedure that should be followed often differs from department to department. One number of staff ought to be appointed to be in charge in investigating the alternatives for making new equipment more energy efficient when the purchase is made. The person in charge ought to be one of the technical purchasers as they are involved early on the purchasing process. Alternatively, responsibility could be given to the purchasing department but by the time the purchasing department sees the offer, it is often too late to change the level of energy efficiency. The person in charge should not investigate the energy saving alternatives available for purchase himself/herself, but he/she should be supporting member for the department’s group of technical purchasers. The person in charge might for example draw up purchasing procedures together with those responsible for the various types of purchase of energy consuming equipment. The format of the procedure for energy efficient implementation should depend on how ambitious the department is in its energy policy and goal. In general, it is recommended that the department should start with a simple procedure for a couple of product areas or departments that are selected on the basis of their expected savings potential. The procedure can then be expended later. The procedure might for example stipulate that for equipment with low energy consumption, suppliers should simply be asked the following three fundamental questions: a) How much energy does equipment consume? b) Are there alternative solutions that consume less energy? c) How much more do they cost, and how long will these costs take to recover?


March 2009 6-7

This will often lead to a fruitful discussion of the savings potential. The most important thing in the first instance is to get a dialogue started with the suppliers and to make them aware of the fact that the energy cost is one of a number of criteria in your selection of new equipment. The suppliers cannot be counted on to bring up this matter of his/her own accord as most suppliers have learned that this is of no interest to their customers. For equipment with an annual energy consumption corresponding to more than RM10,000 – RM 20,000, for example (the limit being fixed in the goal), a detailed evaluation should be made of the criteria the equipment is to meet. The department may choose to do this itself, or to do it in cooperation with the suppliers. Suppliers ought to be instructed to pass on information related to energy consumption of equipment, which is in the tendering phase, so that the energy efficiency of the equipment can be evaluated. The suppliers should also be made aware that, if possible, an alternative offer for a solution that is more energy efficient should be given in addition to their standard offer even though it may be more expensive. 6.6 SOLAR a) Solar Electricity i) Sunlight can be converted into electricity using photovoltaic’s (PV), concentrating solar power

(CSP) and various experimental technologies. PV has mainly been used to power small and medium-sized applications, from the calculator powered by single solar cell to off-grid homes powered by a photovoltaic array.

ii) A solar cell (or photovoltaic cell) is a device that converts light into direct current using the photoelectric effect.

iii) The earliest significant application of solar cells was a back-up power source to the Vanguard satellite, which allowed the satellite to continue transmitting for over a year its chemical battery was exhausted.

iv) Concentrating Solar Power (CSP) system use lenses or mirrors and tracking systems to focus a large area of sunlight into a small beam. The concentrated light is then used as a heat source for a conventional power plant. A wide range of concentrating technologies exists; the most, developed are the solar trough, parabolic dish and solar power tower. These methods vary in the way they track the Sun and focus light. In all these systems a working fluid is heated by the concentrated sunlight, and is then used for power generation or energy storage.

b) Solar Cell A solar cell or photovoltaic cell is made of special materials called semiconductors, the most common semiconductor material which is used in the manufacture of a solar cell is known as silicon. When a light source strikes a solar cell, a portion of it is absorbed by the semiconductor material. The absorbed light energy knocks electrons loose, allowing them to flow freely.


6-8 March 2009

Fig. 6.1 Typical Solar Cell Ordinarily pure silicon is a poor conductor of electricity so impurities such as phosphorus and boron are added to create what is known as a semi-conductor. The addition of these impurities not only allows the silicon to conduct electricity, but also acts to force electrons freed by light absorption to flow in a certain direction. This directional flow of electrons is also referred to as a current. By placing metal contacts on the top and bottom of the solar cell, it then becomes possible to draw that current off to use externally to perform work. c) Solar Electric Module A solar electric module consists of an aluminum framed sheet of highly durable low reflective, tempered glass that has had individual solar cells adhered to the inner glass surface. These individual solar cells are wired together in a series parallel configuration so as to obtain the necessary voltage and current.


January 2009 6-9

d) Solar Panels Solar panels are classified according to their rated power output in Watts. This rating is the amount of power the solar panel would be expected to produce in 1 peak sun hour.

Fig. 6.2 Typical PV Powered Motorised Water Gate Control

Measurement value a) Battery Volt : Voltage reading in the battery b) Inverter AC Amp: AC current reading in the Inverter c) Inverter Battery Volt: Inverter AC voltage that invert from DC to AC. Indication Lamp a) Solar in: To indicate that solar is on and functioning. b) Battery full: To indicate that the Battery is fully charge c) Battery low: To indicate that the Battery is low voltage and required to be charge. d) 48V dc: To indicate the 48Vdc is on. e) Inverter AC volt: AC supply is on.


6-10 March 2009

Device in the Solar Panel a) Solar Charge Regulator: To control the solar system , battery charging and alarm system b) Temp Probe: This is control the panel temp. This is also to on the FAN in the panel. c) Lightning Arrestor : To protect the Lightning surge to the system d) PV Fuse link: This to protect the solar part. e) AC Output to Load Connector AC Distribution from Inverter for output usage: f) Solar input Connector: From Solar input voltage to connect to Solar Charge Regulator. g) 48Vdc Isolator to inverter: To isolate the battery 48Vdc to connect to Inverter. h) AC Inv Input Connector: AC Output from INVERTER connector. i) 48 Vdc Fuse: This is to protect the battery due to high current.

CHAPTER 7 ELECTRICAL SERVICES

Chapter 7 ELECTRICAL SERVICES

March 2009 7-i

Table of Contents


List of Tables ................................................................................................................... 7-iii

7.1 INTRODUCTION .......................................................................................................... 7-1

7.2 ELECTRICAL DRAWING DESIGN.................................................................................... 7-1

7.2.1 Design Procedure and Criteria ........................................................................ 7-1

7.2.2 Coordination with Other Consulting Engineers and Authorities ........................... 7-1

7.2.3 Design Proper ............................................................................................... 7-2

7.2.4 Illumination .................................................................................................. 7-2

7.2.5 Calculation of Average Illuminance and luminance ........................................... 7-2

7.2.6 Arrangement of luminaries ............................................................................. 7-5

7.2.7 Selection of light Source ................................................................................ 7-5

7.2.8 Power determination and estimating procedures .............................................. 7-5

7.2.9 Power Calculation ......................................................................................... 7-5

7.2.10 Cabling selection and design procedures ......................................................... 7-5

7.2.11 Current- Carrying Capacities and Voltage Drops for Cables ............................... 7-5

7.2.12 Voltage Drop ................................................................................................ 7-6

7.2.13 Determination of current-carrying capacity ...................................................... 7-6

7.2.14 Determination of the size of cable to be used .................................................. 7-6

7.2.15 Circuit Breaker Rating .................................................................................... 7-8

7.2.16 Maximum Demand and Diversity Factor ......................................................... 7-8

7.2.17 Schematic Drawing ....................................................................................... 7-8

7.3 415V INTAKE WITH SUPPLY AUTHORITY SUBSTATION, STANDBY GENERATOR SET, AND ITS MAIN SCHEMATIC DRAWING DESIGN. .................................................................... 7-9

7.3.1 Criteria ......................................................................................................... 7-9

7.3.2 System ......................................................................................................... 7-9

7.3.3 Requirement of TNB Substation ...................................................................... 7-9

7.3.4 Main Switch Room ...................................................................................... 7-10

7.3.5 Main Switch Board ...................................................................................... 7-10

7.3.5.1 Circuit Protection ........................................................................ 7-10

7.3.5.2 Switchgears ............................................................................... 7-11

7.3.6 Distribution Board ....................................................................................... 7-11

7.3.7 Generator Set ............................................................................................. 7-11

7.3.7.1 Generator room selection and authority’s requirement ................... 7-11

7.3.7.2 Sizing of Generator ..................................................................... 7-12

7.3.7.3 Maintenance ............................................................................... 7-13


7-ii March 2009

7.3.8 Schematic drawing diagram ......................................................................... 7-15

7.3.9 Power loading connection and the sizing of sub-main cable and protective switchgear .................................................................................................. 7-15

7.4 GENERAL MAINTENANCE ........................................................................................... 7-15

7.4.1 Competent Personnel .................................................................................. 7-15

7.4.1.1 Periodic Inspection...................................................................... 7-15

7.4.1.2 Maintenance of Installation .......................................................... 7-15

APPENDIX 7A SAMPLE ARRANGEMENT OF LIGHTING IN A BUILDING .................................. 7A-1

APPENDIX 7B CORRECTION FACTORS FOR GROUPING ...................................................... 7A-2

APPENDIX 7C CORRECTION FACTORS FOR AMBIENT TEMPERATURE .................................. 7A-3

APPENDIX 7D SINGLE LINE DIAGRAM OF A SIMPLE INSTALLATION .................................... 7A-4

APPENDIX 7E SAMPLE CALCULATION FOR GENERATOR POWER RATING REQUIREMENT ...... 7A-5

APPENDIX 7F SAMPLE INSPECTION FORMAT FOR SWITCHBOARD ...................................... 7A-6

APPENDIX 7G SAMPLE INSPECTION FORMAT FOR GENERATOR SET .................................... 7A-7

APPENDIX 7H SAMPLE SCHEMATIC DIAGRAM FOR POWER SUPPLY SYSTEM ...................... 7A-10

APPENDIX 7H SAMPLE SCHEMATIC DIAGRAM FOR POWER SUPPLY SYSTEM ...................... 7A-10


March 2009 7-iii

List of Tables

Table

Description Page

7.1

7.2

NEMA Code for Start kVA/HP for 3-phase Squirrel Cage Motors

Reduced Voltage Assistance Starting from NEMA Code

7-13

7-13


7-iv March 2009



March 2009 7-1

7 ELECTRICAL SERVICES

7.1 INTRODUCTION Electrical installation work is generally governed by The Electricity Supply Act 1990, and Electricity Supply Regulation 1994.In addition, The IEE Wiring Regulations 16th Edition (BS7671:1992) establishes the standard of wiring design and installation works. 7.2 ELECTRICAL DRAWING DESIGN Electrical design, cost estimation, and drawings are the major workload of electrical service. As such this paper is aimed at giving the procedures generally involved in these aspects of the works which covers design, cost estimation, and drawings of electrical installations for buildings, plants, and machineries etc. 7.2.1 Design Procedure and Criteria A good and functional design is one that is safe, workable, and economical, complies with the relevant regulations and is convenient to the user. All design must comply with: a) The Electricity Supply Act 1990. b) Electricity Supply Regulation 1994. c) The IEE Wiring Regulations 16th Edition (BS7671:1992). d) Department of Health and Safety Requirement. e) Illumination Engineering Society (IES) (UK) Code of Practice. 7.2.2 Coordination with Other Consulting Engineers and Authorities It is necessary for Electrical Engineer to maintain closer liaison with the Architect, and Civil & Structural Engineer for the building layout. The mechanical services proposed location, and their respective power requirement must be obtained from the Mechanical Engineer. It is also essential to consult the client for his requirement regarding the usage of the layout and equipments details if they are separately purchased by the client directly. Finally, the amount of finance available for the work shall be established. A preliminary design is then effected to determine the loading requirement of the installation. The estimated electrical loading will provide fundamental data to establish type of power tariff to apply for power supply from TNB. The power tariff will decide the type of substation, or switching station required by TNB. Similarly the owner’s plant room requirement will vary with different power tariff approved. Once the load details and location intake have been tentatively proposed, the Architect, or the C & S Engineer shall agree with the overall site plan layout. Once the site layout has been finalized, the initial load data has to be prepared and submitted to the Supply Authority that is TNB. All submission to TNB shall comply to TNB’s Guide book. All TNB’s requirement such as substation, switching station etc., must be clearly indicated to the Architect and the C & S Engineer. The client shall be advised with proper Electricity Tariff for application of power supply to TNB. When all parties have agreed with the requirement of loading obtained, detailed design and drawings can commence.


7-2 March 2009

7.2.3 Design Proper The design proper is the design of the electrical installation for the particular project. In its simplest terms the design of electrical installation involves the installation of electrical fittings such as lighting luminaries, fans, switches, switched socket outlets, and equipments such as motors, water heaters and other mechanical machineries etc, and making up the associated circuitry of schematic wiring diagrams showing how they are connected to the incoming supply and also how they are interconnected. 7.2.4 Illumination For the principal purposes of illumination design, light is defined as visually evaluated radiant energy. The visible energy radiated by light sources is found in a narrow band in the electromagnetic spectrum approximately from 380 to 770 nanometers. By extension, the art and science of illumination also include the application of ultraviolet and infrared radiation. The principles of measurement, methods of control, and fundamentals of lighting system and equipment design in these fields are closely parallel to those long established in the lighting practice. Luminous flux is the time rate of flow of light. Lumen is the unit of luminous flux. It is equal to the flux through a unit solid angle from a point light source of one candela or to the flux on a square foot of surface, all point of which are one foot from a point source of one candela. Light source are rated in lumens. Luminous intensity is the luminous flux per unit solid angle in a specific direction. The definition of luminous intensity applies strictly to a light source. Candela (formerly candle) is the unit of luminous intensity. Illuminance is the density of the luminous flux incident on a surface; it is the quotient of the luminous flux by the area of the surface when the latteris uniformly illuminated. Lux (lumen per square metre) is the unit of illuminance. Luminance (photometric brightness) is the quotient of the luminous flux leaving or arriving at an element of a surface and propagated in directions defined by an elementary cone containing the given direction, by the product of the solid angle of the cone, and the area of the orthogonal projection of the element of the surface on a plane perpendicular to the given direction; or it is the luminous intensity of any surface in a given direction per unit of projected area of the surface as viewed from that direction. Candela per square meter (cd/m2) is the unit of luminance. Luminaires are complete lighting units consisting of a lamp or lamps together with the parts designed to distribute the light, to position and protect the lamps, and to connect the lamps to the power supply. 7.2.5 Calculation of Average Illuminance and luminance The design of general lighting systems is governed by room dimensions, structural features, reflectance of room surfaces, mounting height of the luminaires, and the distribution and maintenance characteristics of the luminaire. The choice of the luminaire depends on the service to which it is to be put, which assumes a certain experience in selection, or other aids such as manufactures’ data, which assist the designer in making a selection appropriate from the standpoints of freedom from glare, efficiency, decorative value, and economy. Luminaire’s maximum permissible spacing is given in the photometric report provided by the manufacturer. These spacing limitations are related to the mounting height (usually above the work plane) of direct, semi direct, and general-diffuse lumunaires and to the ceiling height for indirect and semi direct systems.


March 2009 7-3

The distance between luminaries and the wall should not exceed one-half the distance between luminaries. Where desks or benches might be located along the wall, the distance between luminaires and the wall should not exceed 750mm. Average Illumination is the measure of the average concentration of light on a surface. The unit of illumination is the lux as mentioned above. Thus if 50% of the light output of (2) nos. 36W fluorescent lamps ultimately fall on a working plane measuring 3m by 3m. What is the average illumination? The lighting design lumens of the fluorescent lamps are given by the manufacturer to be 3650 lumens.

Total light output = 2 x 3650 lm Light reaching surface = 50/100 x 2 x 3650 =3650 lm Area = 3x 3 m2 Therefore illumination, Eav = incident light (7.1) Area

= 3650 3 x 3 = 405.56 = 406 lux (lm per m2)

Installed Flux is the product of the light output of the luminaire and their number installed. A room is lit by 4 nos. of 1200mm, 36W fluorescent lamps. What is the Installed flux?

Installed flux = 4 x 3650 = 14,600 lm. If working plane =36 m2, then Installed flux per unit area = 14,600 36 = 405.56 =406 lux

Co-efficient of Utilization (CU) is the ratio of the actual flux received on a working plane to the installed flux. It is a measure of the degree to which the installed lamps has been usefully applied. This ratio depends on the proportions of the room, the design of the fitting, and the reflection factors of the rooms’ surfaces. Illumination thus can be expressed as:

E = CU x installed flux per unit area. (7.2) (provided if the lighting installation is perfectly clean)


7-4 March 2009

Room Index , K is given as:

L x W (7.3)

Hm( L+W) Where: L = length of room W = width of room Hm = mounting height of fitting above working plane.

Maintenance factor (MF) is estimated for the effective delivery of average illumination reaching the working surface. Dirt on the fitting has the effect of reducing its light output from it. The conventional assumption is that on average, a lighting installation delivers 80% of the light it would do if it were perfectly clean. Thus the average maintenance factor, MF= 0.8. A higher maintenance factor, say 0.9, can be assumed if the fittings are cleaned regularly, or it could be as low as 0.5 in a foundry. Taking dirt into account, the modified illumination formula is

E = CU x MF x installed flux per unit area. (7.4)

Practical Design Example by considering a classroom of floor dimension 7.5m by 9m and ceiling height of 3m. The lumunaire chosen is 1.2m, 36W fluorescent lamps. IES standards recommended an illumination of 300 lux for reading room. To determine how many lamps are needed to achieve this illumination level? Assume the table top is 0.76 m high, The mounting height is 2.1m, then L= 9m, W= 7.5m, Hm=2.1m.

Room Index, K = L x W Hm( L+W)

= 9 x7.5 2.1x (9+7.5)

= 1.95 = 2 (approximately)

As the ceiling and walls are painted white, reflection factor of ceiling of 70% and walls of 50% can be reasonably assumed. From technical data obtainable from manufacturer, or IES guide book,

Co-efficient of utilization, CU = 0.6 Take maintenance factor, MF = 0.8 Therefore, installed flux required = illumination flux x area CU x MF

= 300(lux) x (9 x7.5) 0.6 x 0.8

= 42,187.5 lm The lighting design lumens (LDL) = 3650 lm of 1 x36W fluorescent lamp Therefore, number of fluorescent = 42,187.5 lamp required. 3650

= 11.6 = 12 nos.(approximately)


March 2009 7-5

If we choose 2 x 36 W fluorescent fittings channel type complete with Al. Reflector, the numbers required will be 6. 7.2.6 Arrangement of luminaries The possible way arranging the six sets of fluorescent luminaries would be to space them equally as shown in Appendix 7A 7.2.7 Selection of light Source The choice of lamp type is clearly of importance in any lighting design. Among the lamp characteristics which have to be taken into account are efficiency, heat output, size, life, robustness and colour properties. Consideration must also be given to any difference in installation and maintenance costs. 7.2.8 Power determination and estimating procedures On receipt of drawings from the Architect, the Electrical Engineer is required to mark estimates of the electrical load for the TNB and costs of the electrical installation for the client or Architect. In order to speed up initial estimates there are several guides or rules of thumb which can be followed:

Light point : 0.1 KW per point Fan Point : 0.06 KW per point Power point c/w 13 A s/o/o : 0.25 KW per point Power point c/w 15 A s/o/o : 0.5 KW per point A/C point c/w 15 A s/o/o : 2.0 KW per point

The figures given above represent the maximum electrical demand for the particular installation if no diversification is applied. The maximum demand in Watt per sq. foot for a typical office is as follows:

Type of load Office Block Lighting 0.9W per sq. foot Air cond. System 4.7 W per sq. foot Future growth, say 20% 1.1 W per sq. foot

7.2.9 Power Calculation The power calculation of a particular electrical installation of a plant or a building shall be based on general guide for each type of circuit given in section 7.1.8 7.2.10 Cabling selection and design procedures The selection of cables for final sub-circuit, sub-mains etc is based on IEE regulation 16th Edition or BS 7671:1992 7.2.11 Current- Carrying Capacities and Voltage Drops for Cables Basis of tables: The tabulated current-carrying capacities correspond to continuous loading and are also known as the “full thermal current rating” of the cables, corresponding to the conductor operating temperature indicated in the headings to the tables.


7-6 March 2009

Cables may be seriously damaged, leading to early failure, or their service lives may be significantly reduced, if they are operated for any prolonged periods at temperature above those corresponding to the tabulated current-carrying capacities. The tabulated current-carrying capacities are base upon an ambient air temperature of 30 C. For other values of ambient air temperature it is necessary to apply a correction factor (multiplier) to obtain the corresponding effective current carrying capacity. 7.2.12 Voltage Drop Values of voltage drop are tabulated for a current of one ampere for a metre run i.e for a distance of 1m along the route taken by the cables, and then present the result of the voltage drops in all the circuit conductor. For any given run the values need to be multiplied by the length of the run in metres and by the current the cables are to carry, in amperes. The voltage drop for any particular cable run must be such that the volt. Drop in the circuit of which the cable forms a part does not exceed 4% of the nominal voltage. For cables up to and including 120mm² they apply with sufficient accuracy where the power factor of the load lies between 0.6 lagging and unity and for larger cables, where the power factor of the load is not worse than 0.8 lagging. In all other cases, the value may be unduly conservative. 7.2.13 Determination of current-carrying capacity In order to determine the current-carrying capacity of the cable, it may be necessary to apply one or more correction factors to the tabulated value given in the appropriate table for the cables. a) For ambient temp. Each table gives the correction factor to be applied depending on the actual ambient temp in the installation. b) For grouping Where a correction factor for grouping has to be applied (see Appendix 7B) c) For thermal insulation For a cable installed in a thermally insulating wall or above a thermally insulated ceiling the cable being in contact with a thermally conductive surface on one side, the rating factor to be applied may, in the absence of more precise information, be taken as 0.75 times the current carrying capacity for that a cable likely to be totally surrounded by thermally insulation material. The applicable rating factor may be as 0.5. 7.2.14 Determination of the size of cable to be used The following procedure enables the designer to determine the size of cable required in order to comply with the requirement for overload protection. If protective device is a circuit breaker divide the nominal current of the protective device by the appropriate ambient temp. correction factor given in the table for type of cable intended to use. These further divided by an applicable correction factor given in Appendix 7C. The size of cable to be used must not less than the value of nominal current of the protection device adjusted as above. The various gears in the electrical installation are connected by means of conductors in the form of wires or cables. Wires or cables of suitable size and type must be chosen in the electrical installation. The criterion used for the voltage drop is permissible.


March 2009 7-7

The regulation stipulates that there must be no more than a 4 % voltage drop of the nominal voltage from the Main Switch Board to any point in the installation. Thus for a 240V system, the maximum voltage drop permissible is 9.6 volts while 16.6 volts is permitted on a 415V system. Table 4D, 4E & 4F etc of the IEE Regulations for the Electrical Equipment of Buildings give current ratings and voltage drop characteristics of various conductors. The voltage drop can be calculated from the formula:-

Voltage = Ic x Vd x l (7.5) 1000 Where Ic = current normally carried by the conductor Vd = mV drop per A per M L = length of cable in M

It is pertinent to point out that the cable rating must always be higher than that of the circuit breaker that is supposed to protect that part of the installation. It is standard practice to use PVC/PVC wires for concealed (not in conduit) wiring. For wiring in conduit PVC wires are used. The widely used underground cables are: PVC/SWA/PVC cable (Polyvinyl chloride/ steel wire armoured / Polyviny chloride cable). This is used with cable gland terminations and is available both in the 3 phase 4 core variety as well as in the single phase 2 core variety. It is generally used when the single phase current demand is less than 60A. An immersion heater rated at 240V, 3kW is to be installed using twin-with –earth PVC insulated and sheathed cable. The feed will be from an existing 15A spare way Circuit breaker and will run for much of its 14m length in a roof space which is thermally insulated with glass fibre. Ambient temperature is expected to be 35 C. when leaving the consumer unit the cable will be bunched with seven other twin-with–earth cables. Solution: Determine whether the 15A circuit breaker will be adequate.

I=P/V=3000/240=12.5A The protection rating (15A), not the circuit rating, must be divided by each of a) The group correction factor – from table B1 eight multi-core cable on a wall, the factor = 0.52 b) The ambient temp. factor - from Table 4C1 of this chapter the ambient temp. factor 0.94 c) The thermal insulation factor- since the cable can be cooled on one side this the thermal

insulation factor is 0.96. The calculation then becomes:

Required Rating = 15 = 31.97A 0.52 x 0.94 x 0.96

The next step is to find from table 4D1A (Refer of IEE 16th edition). Since the cable concerned will be clipped direct to surface, it can be seen that 6mm cable must be selected with a current rating of 43A fore one twin cable with protective conductor. For other of cable or conduct or the relevant tables can be referred from the IEE 16 th Edition.


7-8 March 2009

The TNB needs to know the expected power demand of the installation in order to lay a suitable cable for the incoming supply. This can be dealt with using the maximum demand plus diversity factor criteria together with the methods outlined in the section for estimating procedures. The design of the final sub-circuits must be done in accordance with the IEE Regulations (control, distribution and Excess Current Protection). 7.2.15 Circuit Breaker Rating It helps a lot, however, to keep the following rules in mind:-

Circuit Rating

Size of Wire No. of Point per Circuit

5A 1.5mm2 8 Nos. of lighting or fan points or 1 Nos of 5A

15A 2.5mm2 1 Nos. 13A switch socket outlet

20A 2.5mm2 2 Nos 13A s/s/o

30A(ring) 2.5mm2 10Nos 13A s/s/o provided they are all located within an area of more than 1,000 sq. ft.

30A(radial) 4.0mm2 6 Nos 13A s/s/o A factor of 0.8 is normally applied to the specified rating of the distribution cable,i.e. not more than a 4A load on a 5A sub-circuit. This ensures that the circuit breaker rating is standard circuit breaker Rating available. 7.2.16 Maximum Demand and Diversity Factor The term maximum demand refers to the expected maximum power requirement of an installation. This value is given by the product of the total connected load and the Diversity factor: M.D. =T.C.L. x D.F. Where: M.D = Maximum Demand T.C.L = Total Connected Load D.F = Diversity Factor Knowledge of this value enables TNB to determine the size of their incoming cable. The total connected load is the load expected to be connected to the system while the diversity factor is a weighting factor that is used to simulate actual loading conditions. The IEE Regulations provides a table which enable one to estimate the maximum current which will flow in an installation so as enable to calculate the size of cables, and switchgears. However, one shall note that no diversity is to be allowed for when calculating the size of circuit conductors and switchgear for final sub-circuit. 7.2.17 Schematic Drawing For the design of schematic diagram, the power loading of both lighting and general power requirement shall be calculated and planned. Typical single line diagram of a simple installation is as shown in Appendix 7D.


March 2009 7-9

7.3 415V INTAKE WITH SUPPLY AUTHORITY SUBSTATION, STANDBY GENERATOR SET, AND ITS MAIN SCHEMATIC DRAWING DESIGN. 7.3.1 Criteria In the case of 415V intake, the supply authority, TNB, generally would request for a substation if the estimated maximum demand of the load exceeds 100 KVA. 7.3.2 System In this system, the supply authority will give 415V supply up to the main switchboard in the main switchroom which is usually annexed to the supply authority’s substation. If L.V. supply is taken, the TNB requires a H.V.switch room and a transformer room which should be adjacent to each other although in the case of a substation compartment, the H.V.switchgears and transformer(s) may be housed in the same room to save space. The consumer is required to provide a main switch room adjacent to TNB transformer room besides the generator set room. Besides space, location for the above rooms is also important and few of the essential requirements for these rooms are:- a) They should located within the building where the load centre is, b) They should be near to one another, c) They should be easily accessible by vehicles and personnel for installation, operation

maintenance and breakdown purpose, d) They should be easily accessible to heavy plant during installation and when replacement is

necessary. e) They should have adequate ventilation and security from flood. In addition to the above rooms there should be electrical service ducts to house vertical submains to loads at upper floor and roof level such as lift machines and air conditioning plants and vertical rising mains for lateral distribution at individual floors. Rising ducts reserved for electrical risers should be located as close the L.V. switch room as possible. They should be centrally located in the building to minimize unnecessary long run of final circuits. As underground cables enter and leave the building at a depth of about 760mm, there should be no structural obstruction such as ground beams and pile s at this depth. For very high rise buildings or in the case where heavy loads are located at high levels, it may be necessary to provide substations at these levels. In this case the floors for these sub-stations must be specially designed to take the equipment load. All the requirements mentioned above call for early planning and close liaison and coordination with the architect and structural engineer. 7.3.3 Requirement of TNB Substation After the location and size of the substation have been agreed with TNB, details of substation requirement should be obtained from TNB District Manager concerned as soon as possible Details of building and civil work should be passed to the architect to be included in the building contract. Generally TNB does not allow other services to pass through the substation. Details regarding the size, location and land title of the substation should be given to TNB to prepare the necessary lease agreement. Mechanical services such as automatic fire fighting system for the substation shall be designed for.


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As for electrical requirement TNB requires the consumer to provide lighting points and switch socket outlets to be terminated at a DFB or splitter unit. If L.V. supply is not available in TNB substation, it has to be provided by the consumer by taking supply from the main switchboard. 7.3.4 Main Switch Room Main switch room (also subswitch rooms, if any) should be big enough to permit easy installation and maintenance. Usually not less than 0.7m clearance should be allowed between the wall and the rear of the switchboard. Front clearance of the switchboard should be such that there is still sufficient passage space with the switch gears full withdrawn. The minimum length of the switch room should be equal to the length of the switchboard plus 1.2m. Cable trench in the switch room is usually about 0.75m wide so that while the trench is not unnecessarily congested with cables, the switchboard can still sit with 150mm to each side of the trench. Main switch room should have external door for easy access from the exterior of the building. 7.3.5 Main Switch Board Main switchboard is normally of the self-contained, floor mounted, flush fronted, metalclad cubicle type suitable for front and rear access. It shall be designed to with stand fault condition of not less than 31 MVA at 415V for 1 second as defined in B.S.5486. Air circuit breaker is normally used as incoming switchgear. It shall have minimum breaking capacity of 31 MVA at 415V with a short time rating of 1 second. Other components are protection relays, ammeters, voltmeters, power factor meters, or micro-processed based digital power meters, current transformer, etc. The MSB must be capable of withstanding certain fault and load conditions and should be positioned at a suitable location with respect to accessibility, ease of operation and length of cable run with adequate ventilation ensured. It shall be fabricated by Switch Board manufacturer approved by Suruhanjaya Tenaga. Sometimes two transformers are supplied by TNB. This may happen when:- a) A single transformer is insufficient to cater for the total load of the installation, or b) A more secured supply system for the installation is required. Whatever the cause maybe, the main switchboard must be designed to receive the two incoming feeders from the separate transformer. In this case it is normal practice to incorporate a 4 pole coupler between the two sections of main busbars fed by the two transformers to provide further flexibility in the supply system. The coupler must at least be mechanically interlocked with the other two incoming A.C.B.’s is opened in order to satisfy TNB’s requirement. 7.3.5.1 Circuit Protection Generally the main incoming breaker should be provided with both O/C & E/F (either IDMT or instantaneous type) protection. Outgoing breakers may be provided with O/C or O/C & EF (instantaneous type) depending on the circuit design. As the majority of electrical faults in government buildings are attributed to earth fault, it is advisable to provide the main incoming breaker with IDMT E/F protection to achieve a better discrimination between the outgoing circuits and the main incoming breaker thus reducing the occurance of the total power failure to the building.


March 2009 7-11

7.3.5.2 Switchgears The switchgears normally encountered are the ordinary lamp and socket outlet switches, isolators fuse switches, switchfuse, circuit breakers, changeover switches and contactors. Given below are some useful notes on the more commonly used protective and isolating devices. a) Isolators - These are used for local isolation only. They are not used for

cable protection.

b) Switch fuse/ switch fuse- This is a single unit made up of an isolator in series with an HRC fuse the HRC Fuse being retractable. It comes in both SP & N and TP & N configurations with standard rating being 20A, 30A, 45A and 60A.

c) MCCB This is both an isolating as well as a protective device to control loads above 100A to 400A

d) Air-circuit-breakers - These together with over-current and earth leakage relays are used for busbar ratings of 400A and above. They are expensive but efficient tripping devices.

MCBs and MCCBs are generally being introduced to replace h.r.c.fuses, switch fuses, and even air circuit breakers on account of their compact size, ease of maintenance and neat appearance when incorporated into cubicles. The choice of circuit breaker must conform to the fault level designed for. The interrupting capacity of the circuit breaker must be equal to or greater than the amount of fault current that can be delivered at the point in the system where the breaker is applied. The amount of fault current supplied by a system can be calculated at any point in the system. The following interrupting capacities should be considered for the 240/415V system:- Main Switch Board : 43 KA(31MVA) to 32 KA(23MVA) SUB Switch Board : 22KA 916MVA) to 14 KA(10MVA) Distribution Board : 10KA to 6 KA 7.3.6 Distribution Board Distribution board normally is wall mounted type. It consists of isolating switchgears, final sub circuit breakers for over current and earth leakage protection. The mounting height for a distribution board shall be 2m measured from the floor to the underside of the distribution board. 7.3.7 Generator Set 7.3.7.1 Generator room selection and authority’s requirement Siting of generator set room and layout of generator set are important as they affect the performance of the equipment. Generator set room should have as many external walls as possible. In any case it is not advisable to have less than 2 external walls. The minimum clearance height of the generator set room should be given careful consideration during planning stage. If the minimum clearance height is insufficient, the exhaust system may not be able to be properly installed resulting in high back pressure. This affects the performance of the generator set and increases the noise level as well.


7-12 March 2009

Generator set should be so installed that radiator can discharge the hot air through an external wall away from occupied areas. Air intake should preferably be from the opposite side of the wall through which the radiator discharges the hot air. If the construction of the room is such that the volume of intake air is insufficient, then forced air intake by means of electric blower fan has to be installed. It shall be noted that the installation of generator set must comply with the requirement of DOE and Suruhanjaya Tenaga. 7.3.7.2 Sizing of Generator Special attention has to be paid to the selection of standby generator set as it is invariably used to supply power to inductive loads like lifts, electric motors etc. The inrush current during the starting of these inductive motors causes voltage dip in the generator. This means when sizing the capacity of a standby generator set, one has to consider both the KW capacity of the peak load as well as voltage dip requirement. Sometimes standby generator set has to supply thyristor loads such as UPS in which case special attention also be given when sizing the generator capacity due to the presence of harmonics. Example: To determine the generator and engine power rating requirement for the pumping station with the following loads:- Operating Office and Control house:- a) general lighting load = 12 A b) small power for computers and office equipments = 6 A c) 2 nos. of air conditioning system for office = 10 A d) 3 nos. of 10h.p. motors for water pumps with star-delta starter Assuming that the 2 nos. of office air conditioning units do not cause much voltage dip compared to the water pump units; the total load with no pumps operating = 12+6+10 = 28 A The motor loads when connected to generating set would cause large voltage and frequency deviations. Holding coils could drop out, chattering of motor starts could happen, and stalling of motor speed during operation might happen. The generating set should be selected for both starting and running the loads. Consulting engineers must, therefore provide motor starting characteristics to make the selection of generating set a possibility. This means that motor suppliers must provide the relevant technical performance data to the consulting engineers. The data must include Start kVA, Run kVA, Start kWe, Run kWe, efficiency, power factor, etc. This information sometimes can be difficult to obtain. If such is the case, then the National Electric Manufacturers Association of United States of America (NEMA), Practice on the Design Code for Motors is to be used to estimate the Start kVA. Table 1 is the NEMA Code for 3-phase Squirrel cage motors.


March 2009 7-13

Table 7.1 NEMA Code for Start kVA/HP for 3-phase Squirrel Cage Motors

Remarks : If Start kVA is not known, use the higher value.

Code StartkVA/HP Mostly Used On A 0 – 3.15 B 3.15 – 3.55 Normal Torque, Low Starting Current C 3.55 – 4.00 High Torque, Low Starting Current D 4.00 – 4.50 High Torque, High Slip E 4.50 – 5.0 F 5.0 – 5.6 >15 Hp G 5.6 – 6.3 10Hp H 6.3 – 7.1 < 7.5 HP but > 5 HP J 7.1 – 8.0 3 HP K 8.0 – 9.0 > 1.5 HP but < 2 HP L 9.0 – 10.0 1 HP M 10.0 – 11.2 < 1HP etc

Table 7.2 Reduced Voltage Assistance Starting from NEMA Code

Code Starting Method Starting kVA (%) Starting Torque (%)

C Reactor or Resistance 80% Tap 80 64 D Start - Delta 33 33 E Half Winding 65 50

The calculation shall be based on NEMA standard for estimating the starting KVA for the water pump motor. Sample of calculation shall be tabled in Appendix 7E 7.3.7.3 Maintenance Maintenance can be divided into:- a) Correction maintenance

- All maintenance performed in order to correct to failure b) Preventive maintenance

- Direct preventive maintenance performed in order to prevent failure from accuring (eg. Cleaning lubrication at regular intervals).

- Indirect Preventive maintenance or condition monitoring are all measures taken to discover faults before they result in operational disturbances or unnecessary damage (eg. Performance monitoring and testing)


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Maintenance Support Documents To effectively implement maintenance documents pertaining to the design and the equipments are essential, these documents are:- a) Design b) Specification c) Instruction d) Manuals – such as technical specification, operator instructions cards, operating manuals

maintenance manual, maintenance instruction cards, wall diagrams, work instruction cards, work specification spare parks data etc.

Testing This is part of indirect Preventive Maintenance. It could be done either by objective monitoring i.e by using testing instruments on by subjective monitoring i.e by visual inspection Refer to the IEE regulations Part 7 which deals into the testing and inspection of installation following a logical sequence or phases of work to produce a complete installation. All protective devices and residual current circuit breaker should be tested to ensure that they perform their protective function when called to do so. A sample inspection format for switchboard & gen-set is shown in Appendix 7F & E-G respectively. Safety It is essential that all plant and equipment is tendered and kept safe whilst it is being worked on. Part 7 on the IEE regulation emphasizes on good workmanship and usage of proper materials. Examples of good practice are:- a) No work should be carried on Live. All dead equipment must be effectively earthed before

commencement of work. b) Only authorized and competent person may work on electrical equipment. c) The procedure for effecting shutdown and resuming supply be clear cut and foolproof. d) Proper ladders, safety belts and other relevant safety devices should be used when working on

overhead lines. e) Full sets of specialized tools should be available. f) Guidance issued by the Machinery Department on the operation of plant and equipment should

be strictly followed and the responsible officer should ensure that due notice is taken of such information.

g) Working areas associated with sump, pits, walls, air shalt etc, must be guarded and warning

notices displayed safety guards must be securely fixed and safety devices left operational.


March 2009 7-15

The requirements for a competent electrical staff to maintain the electrical installation are clearly stated in the Electricity Act of Malaysia 1994 Section IV – Maintenance requirements of qualified wireman, chargemen of various grade shall comply with the Electricity Act of Malaysia 1994. 7.3.8 Schematic drawing diagram The main schematic drawing diagram for a power supply system of 415 V shall consist of a main switch board which shall contain switchgears that can efficiently and effectively cut off power supply to prevent danger. The main switch board shall consist of components and switchgears as described in section 7.3.5. Where standby generator is required, section 7.3.7 has clearly defined the sizing of it. The overall sample of schematic drawing diagram is as shown in Appendix 7H. 7.3.9 Power loading connection and the sizing of sub-main cable and protective switchgear The electrical loading connected from each sub-board or control panel shall be identified properly for its total connected load and applying appropriate diversity factor to obtain correct maximum demand required. The sub-main cable and its protective circuit breaker shall be sized as describe in section 7.1 However, the overall total connected load, and maximum demand of a main switch board shall be the summation of all sub-boards and control panels connected to it. The size of main circuit breaker and the main busbar shall be able to withstand the total connected load plus 20% additional spare capacities, or the total future load estimated. The maximum capacity shall also need to match with the capacity of the transformer which is feeding the main switch board. All protection relays shall be properly calibrated by competent service electrical engineer. 7.4 GENERAL MAINTENANCE Each and every electrical Installation shall be periodically inspected, tested, and effectively operated and maintained by competent personnel as required by the current electricity regulation of Malaysia. 7.4.1 Competent Personnel All Electrical competent personnel shall be registered with The Suruhanjaya Tenaga of Malaysia. They are:- a) Electrical Service Engineer, b) Electrical competent Engineer, c) Electrical charge man, d) Electrical Wireman, e) Electrical cable jointer. 7.4.1.1 Periodic Inspection Any electrical installation which required 100A and above, shall be monthly inspected by Competent Electrical Engineer. The schedule shall follow the current electricity regulations, 1994, clause (67), sub-clause (2). 7.4.1.2 Maintenance of Installation Each installation shall be well maintained by competent personnel. For low voltage, 415 V system, it shall be operated, or maintained by licensed three phase wireman.


7-16 March 2009

If the low voltage system is supported by standby generator set, competent personnel to operate and maintain it shall be a charge man of relevant grade issued by Suruhanjaya Tenaga. Similarly, all median voltage (11KV) system, a charge man of grade B-one is required. All protection relays of electrical switchboards, or control panels shall be recalibrated by licensed electrical serviced engineer once in every two years. Detailed requirements shall comply to current electricity regulations.


March 2009 7A-1

APPENDIX 7A SAMPLE ARRANGEMENT OF LIGHTING IN A BUILDING


7A-2 March 2009

APPENDIX 7B CORRECTION FACTORS FOR GROUPING

Correction factors for groups of more than one circuit of single-core cable, or more than one multicore cable

* Spaced by clearance between adjacent surfaces of at least one cable diameter (De). Where the horizontal clearances between adjacent cables exceed 2De no correction factor need be applied. ** When cables having differing conductor operating temperatures are grouped together, the current rating shall be based upon the lowest operating temperature of any cable in the group.


March 2009 7A-3

APPENDIX 7C CORRECTION FACTORS FOR AMBIENT TEMPERATURE

Correction factors for ambient temperature where protection is against short- circuit. NOTE: This table appliers where the associated overcurrent protective device is intended to provide short-circuit protection only. Except where the device is a semi-enclosed fuse to BS 3036 the table also applies where the device is intended to provide overload protection.

NOTES: 1). Correction factors for flexible cords and for 85°C or 105°C rubber- insulated flexible cables are

given in the relevant table of current- carrying capacity. 2). This table also applies when determining the current-carrying capacity of a cable.


7A-4 March 2009

APPENDIX 7D SINGLE LINE DIAGRAM OF A SIMPLE INSTALLATION

Appendix 7-D


March 2009 7A-5

APPENDIX 7E SAMPLE CALCULATION FOR GENERATOR POWER RATING REQUIREMENT

Calculating the generator power rating requirement for the pumping station with the following loads:- Starting Running

Item KVA KW KVA KW Total lighting and small 17.5 Power loads (G.L.) 20.13 28x0.415x1.732x0.85 =17.1KW . Start the 1st pump 10hpx5.3kVA/hp 53 53kVAx0.85pf 45 Add G.L.load 20.13 17.5 20.13 17.5 Total 73.13 62.5 20.13 17.5 Run the 1st pump At 0.88 efficiency 10hpx0.746KW/hpx1/0.88 10.0 8.5 Add G.L .load 20.13 17.5 Total 30.13 26.0 Start the 2nd pump 10hpx5.3kVA/hp 53 53kVAx0.85pf 45 Run 1st pump and G.L .load 30.13 26 30.13 26 Total 83.13 71 30.13 26 Run the 2 pump At 0.88 efficiency 10hpx2x0.746KW/hpx1/0.88 19.95 16.96 Add G.L .load 20.13 17.5 Total 40.08 34.46 Start the 3rd pump 10hpx5.3kVA/hp 53 53kVAx0.85pf 45 Run 2 pump and G.L. load 40.08 34.46 40.08 34.46 Total 93.08 79.46 40.08 34.46 Run the 3 pump At 0.88 efficiency 10hpx3x0.746KW/hpx1/0.88 29.92 25.43 Add G.L .load 20.13 17.5 Total 50.05 42.93

The critical generator loads are the KVA and KW for starting the third pump. During the start, the first two running motors can act momentarily for half a cycle as generators and, hence, reduce the demand on the generator, but the effect lasts much less than a second and is difficult to assess, so the effect is ignored, especially as it may take up to 6 second to start the 3rd pump. The calculated KVA required is 93.08 KVA. Assuming that the generator efficiency as 0.85, the aging factor for 5 years is 0.8 and additional spare capacity required is 20%.

The generator size is = 93.08x 1.2 KVA 0.85x0.8

= 164.26 KVA Hence the generator size selected shall be 175 KVA


7A-6 March 2009

APPENDIX 7F SAMPLE INSPECTION FORMAT FOR SWITCHBOARD

MAIN SWITCHBOARD INSPECTION CHECK LIST TITLE OF PROJECT: ITEM DESCRIPTION CONDITION REMARK

A Main Switch Room

A.1 Clean the M.S. Room

A.2 Record all main switch gears calibration value into the log book.

A.3 Check all indicating lighting.

A.4 Check all metering panel:- (a) Voltmeter (b) Ammeter or Digital multimeter

A.5 Date of calibration for all switchgears protection relays

A.6 Check all labeling are in order.

A.7 As built drawing condition in order.

A.8 CPR chart available.

A.9 Rubber floor mat available.

A.10 Fire fighting system licensed valid. A.11 Physical condition in order.


March 2009 7A-7

APPENDIX 7G SAMPLE INSPECTION FORMAT FOR GENERATOR SET

GENERATOR SET INSPECTION CHECK LIST TITLE OF PROJECT: ITEM DESCRIPTION CONDITION REMARK

A Generator Room

A.1 Clean the generator room

A.2 Record all generator set parameters into the log book B Lubricating System

B.1 Check lubricating oil level, replenish if necessary

B.2 Change lubricating oil filters half-yearly or 250 hours whichever

occurs first.

B.3 Check hydraulic governor oil level, replenish if necessary

B.4 Check hydraulic governor oil at 12th month or 1500 hrs whichever

occurs first.

B.5 Visual inspection for indication of unusual conditions. C Fuel System

C.1 Check operation of fuel transfer pumps.

C.2 Change fuel filters half-yearly or 250 hours whichever occurs first.

C.3 Visual inspection for indication of fuel leaks.

C.4 Check and clean air intake filters

C.5 Change air intake filters D Cooling System

D.1 Check coolant level, replenish if necessary.

D.2 Check condition of hose and connections


7A-8 March 2009

D.3 Change coolant and coolant filters

D.4 Check coolant and clean radiator

D.5 Check conditions of fan belts, tension if necessary E Electrical System

E.1 Check battery electrolyte level and specific gravity, replenish if

Necessary.

E.2 Check the conditions of the battery charger and / or battery

Charging alternator. F Alternator

F.1 Check and clean vent screens

F.2 Check and grease the bearings. G Generator Set Control Board And Switchboards

G.1 Inspect and service the control system, meters, Appearance, etc.

G.2 Check the indicator lamps. Replace if necessary. H General

H.1 Run the generator set without load for 30 minutes.

H.2 Simulate mains failure. Check and test the operation of

ATSE.

H.3 Run the generator set on load.

H.4 Check and test the operation of protective devices for the generator set: (a) Low lubricating oil pressure - warning and trip (b) High lubricating oil temperature - warning and trip © High exhaust temperature - warning and trip


March 2009 7A-9

(d) High jacket water temperature - warning and trip (e) Low radiator water level - warning and trip (f) Fail to start - warning and trip (g) Overspeed - warning and trip (h) Low batter voltage - warning and trip (i) Low fuel level (1st stage) - warning and trip (j) Low fuel level (2nd stage) - warning and trip (k) Fuel pump runaway

- warning and trip by shut-off fuel supply to the engine


7A-10 March 2009

APPENDIX 7H SAMPLE SCHEMATIC DIAGRAM FOR POWER SUPPLY SYSTEM

AP

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DIX

7H

S

AM

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SCH

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RP

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March 2009 7A-11

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7A-12 March 2009


CHAPTER 8 DREDGER

Chapter 8 DREDGER

March 2009 8-i

Table of Contents


List of Tables ......................................................................................................................... 8-ii


8.1 INTRODUCTION .......................................................................................................... 8-1

8.2 USAGE OF DREDGER ....................................................................................................... 8-1

8.3 TYPES OF DREDGER .................................................................................................... 8-2

8.4 EQUIPMENT OF DREDGER ........................................................................................... 8-8

8.5 DISPOSAL OF MATERIALS ............................................................................................ 8-9

8.6 METHOD OF MEASUREMENT AND PAYMENT ................................................................. 8-11

8.7 BUILT UP RATES FOR FILLING & PROFILING WORKS ................................................... 8-13

8.8 ORGANISATION AND RESPONSIBILITY ....................................................................... 8-15

8.9 COMPETENCY............................................................................................................ 8-15

8.10 SAFETY ..................................................................................................................... 8-17

8.11 OPERATIONAL TRAINING ........................................................................................... 8-19

8.12 OPERATION & MAINTENANCE ...................................................................................... 8-20

8.13 MAINTENANCE TRAINING .......................................................................................... 8-20

8.14 SAMPLE OPERATING PROCEDURES ............................................................................. 8-20

8.15 SAMPLE MAINTENANCE CHECKLIST ............................................................................ 8-21

Chapter 8 DREDGER

8-ii March 2009

List of Tables

Table

Description Page

8.1

8.2

8.3

8.4

8.5

Class of Dredgers

Types of Dredging Equipment and Characteristics

Disposal Systems

Cost Worksheet - Built Up Rates for Dredging Works

Built Up Rates for Filling & Profiling Works

8-4

8-7

8-10

8-11

8-13

List of Figures

Figure

Description Page

8.1

8.2

8.3

8.4

8.5

8.6

Typical Dredger

Typical Hopper Dredge Systems

Trailing Suction Hopper Dragger

Typical Cutter Dredge System

Cutter Suction Dredger (Typical)

Simplified Cutter Diagram

8-1

8-2

8-3

8-5

8-6

8-21

Chapter 8 DREDGER

March 2009 8-1

8 DREDGER

8.1 INTRODUCTION Dredging is an excavation activity or operation usually carried out at least partly underwater, in shallow seas or fresh water areas with the purpose of gathering up bottom sediments and disposing them at a different location. A dredge is a device for scraping or sucking the seabed material used for dredging. A dredger is a ship or boat equipped with a dredge. Basic objectives of dredging include: a) Increasing / maintaining the depth of water in a navigation channel b) Spot excavations preparatory to major waterfront construction (bridges, piers, or dock

foundations) c) Harvesting sand (for construction and beach restoration) d) Waterways management and maintenance for flood and erosion control e) Mining sediment material to recover valuable substances (like gold dust) The process of dredging creates spoils (excess material), which are conveyed to a location away from the dredged area. Dredging can produce materials for land reclamation or other purposes (usually construction-related), and has also historically played a significant role in gold mining. Dredging can create disturbance in aquatic ecosystems, often with adverse impacts.

Fig. 8.1 Typical Dredger

8.2 USAGE OF DREDGER a) Capital dredging: to create a new harbour, berth or waterway, or to deepen existing facilities in

order to allow larger ships access. This process is usually carried out with a cutter-suction dredge. b) Maintenance dredging: deepening navigable waterways which have become silted with the

passage of time, due to sand and mud deposited, until they may become too shallow for navigation. This is often carried out with a trailing suction hopper dredge.

c) Land reclamation: mining sand, clay or rock from the seabed and using it to construct new land elsewhere. This is typically performed by a cutter-suction dredge or trailing suction hopper dredge.

Chapter 8 DREDGER

8-2 March 2009

d) Beach nourishment: mining sand offshore and placing on a beach to replace sand eroded by storms

or wave action. This is done to enhance the recreational and protective function of the beaches, which can be eroded by human activity or by storms. This is typically performed by a cutter-suction dredge or trailing suction hopper dredge.

e) Removing trash and debris: often done in combination with maintenance dredging, this process removes non-natural matter from the bottoms of rivers and canals and harbors.

8.3 TYPES OF DREDGER a) Self propelled b) Non propelled a) Self propelled dredger

i) Water Injection Dredger - A water injection dredger injects water in a small jet under low pressure (low pressure

because the sediment should not explode into the surrounding waters, rather it is carefully moved to another location) into the seabed to bring the sediment in suspension, which then becomes a turbidity current, which flows away down slope, is moved by a second burst of water from the WID or is carried away in natural currents.

- As a side note: Water injection results in a lot of sediments in the water which makes measurement with most hydrographic equipment (for instance: singlebeam echosounder) difficult and should make use of filtering to produce better results.

ii) Trailing suction hopper dredger - A trailing suction hopper dredger (TSHD) trails its suction pipe when working, and loads the

dredge spoil into one or more hoppers in the vessel. When the hoppers are full the TSHD sails to a disposal area and either dumps the material through doors or pumps the material out of the hoppers.

Fig. 8.2 Typical Hopper Dredge Systems

Chapter 8 DREDGER

March 2009 8-3

In general, a trailing suction hopper dredger (TSHD) is a vessel that is suited for deep-sea navigation with the ability to load dredged materials into its own hold, the so-called hopper, by means of centrifugal pump(s) and suction pipe(s).TSHD's are fully maneuverable, as they are required to sail during dredging operations. When a TSHD approaches the dredge area it will reduce its sailing speed and lower the suction pipe(s) overboard. The draghead(s) at the end of the suction pipe(s) will be kept above the seabed until the dredge area has been reached. The dredge pump(s) will be started. The water that is thus taken in, prior to the draghead(s) touching the seabed, will be pumped overboard or in some cases in the hopper of the vessel. Upon arrival at the dredge area the draghead(s) will be lowered onto the seabed. Due to the forward movement of the vessel the draghead(s) will loosen the seabed material. In this way a mixture of soil and water enters The suction pipe and loaded directly into the hopper. Water jets, which may be on the draghead(s), can assist in loosening the soil, hence optimising the production.

Fig. 8.3 Trailing Suction Hopper Dragger

While dredging, the TSHD will sail at a speed of 1 to 3 knots, dependant on the dredge location, surrounding marine activities, sea condition and soil parameters.

The actual position of the draghead(s) and the suction pipe(s) in relation to the position of the vessel can be checked through the following measurements:

By measuring the angle of the vessel in combination with the draught and trim of the vessel and combining these measurements with those of the draghead(s) and the suction pipe(s), the latter can be determined through measurement devices mounted on the draghead(s) and the suction pipe(s), which indicate the angles of the different parts of the suction pipe(s).

The depths of the different parts of the draghead(s) and the suction pipe(s) can be determined by using pressure readings from specially installed sensors on the draghead(s) and the suction pipe(s).

Chapter 8 DREDGER

8-4 March 2009

As a backup system an open ended thin tube is installed from the start of the suction pipe down to the draghead, through which air can be pumped under pressure. The air pressure at the exact moment bubbles appear on the surface is a measure for the depth.

For each category of dredging work a matching class of dredgers is created. Hopper volumes are used for indication of dredgers capacity. The following volume classes have been identified. The classes, or categories, have been named after their main purpose characteristic.

Table 8.1 Class of Dredgers

CATEGORY FROM UP TO AND INCLUDING Small size TSHD 500m3 4000m3 Medium sized TSHD 4,000m3 9,000m3 Large sized TSHD 9,000m3 17,000m3 Jumbo TSHD 17,000m3 35,000m3

b) Non propelled dredger i) Mechanical Types

Bucket ladder dredger The bucket ladder dredger is equipped with multi-buckets attached to a rotary wheel or connected to a continuous chain. The bucket lifts the dredged material onto a conveyor or chute to transfer to the alongside barges.

Grab dredger The grab dredger picks up seabed material with a clam shell grab which suspended by cables form the on-board crane. The grab is lowered to the bottom and pick up material by “bitwig operation”. The dredged material is then deposited into barges or scows alongside the dredger. Most of these dredges are equipped with spuds when working in swampy overgrown vegetation area. Backhoe dredger A backhoe/dipper dredge has a backhoe similar to an excavator. A crude but usable backhoe dredger can be made by mounting a land-based backhoe excavator on a pontoon. Small backhoe dredgers can be track mounted and work from the bank of ditches. A backhoe dredger is equipped with half-open shell. The shell is dropped to the bottom and digs out the material to fill the bucket. Usually dredges material is loaded in barges. This machine is mainly used in harbors and other shallow water.

ii) Hydraulics Dredge

Suction dredger Suction dredger is similar to a floating pumping station. It sucks up material through the intake pipe on the dredger, the mixture is then pumped through a discharge pipeline to the disposal site. It is mainly used in loose deposits.

Chapter 8 DREDGER

March 2009 8-5

Cutter suction dredger

A cutter-suction dredger's (CSD) suction tube has a cutter head at the suction intake, to loosen the bottom materials to the suction mouth. The cutter can also be used for hard surface materials like gravel or rock. The dredged material is usually sucked up by a wear resistant centrifugal pump and discharged through a pipe line or to a barge. In recent years dredgers with more special design cutterhead have been built in order to dislodge harder and harder rock without blasting.

Automation System

Suction / Discharge System

Coupling System

Cutting System

Fig. 8.4 Typical Cutter Dredge System

A cutter suction dredger is a stationary dredger. It consists of a pontoon, which is positioned with a spud pole at the back and two side anchors at the front. The material to be dredged is loosened by a rotating cutter head, the so-called cutter. The cutter head, which may be electrically or hydraulically driven, is attached to the end of the suction intake of a centrifugal dredge pump. It is mounted at the extremity of a fabricated steel structure, the so-called cutter ladder, which is attached to the main hull by heavy hinges, which permit movement in the vertical plane. The ladder assembly is lowered and raised by means of a hoisting winch (or occasionally hydraulic cylinders) controlled from the bridge.

Chapter 8 DREDGER

8-6 March 2009

Fig. 8.5 Cutter Suction Dredger (Typical)

By means of swing winches, the cutter (and therefore the whole pontoon), is pulled in turns to the portside and starboard-side anchor whilst turning on the fixed spud pole. In this way (part of a circular movement is made, whilst a so-called spud pole carrier enables a forward movement of the dredger.

The vertical position of the cutter head and the cutter ladder can be determined by any of the following ways:

- By measuring the length of a thin wire connected from the cutter ladder to the pontoon,

through sheaves etc. - By measuring the angle between the ladder and the pontoon in combination with draught and

trim of the pontoon. - The depth of the cutter head can also be determined by using pressure readings from specially

installed sensors.

Through the above-mentioned measures a CSD is able to determine the depth and the angle of the cutter head while dredging. After cutting the soil and transporting it through the onboard suction lines, the dredged material can be discharged in either one of the following ways:

- Through a floating pipeline and / or a submerged pipeline; - Through a barge loading facility; - By side-casting directly onto the seabed in an adjacent area.

Chapter 8 DREDGER

March 2009 8-7

Types of dredging equipment and characteristics

Table 8.2 Types of Dredging Equipment and Characteristics Type of Equipment

Operating Conditions

Min water depths, m

Max water depths, m

Add. Features / characteristics

Capacity, m3

Trailing suction hopper dredge

Can operate in rough seas

15-30 100 Bottom placement 100,000 – 500, 000 / week

Cutter suction dredge and suction dredge

Light to moderate sea conditions (H=1m)

25 60-80 Discharge of material through pipeline or loading onto barge

50,000 – 500, 000 / week

Hydraulic unloader

Operates in sheltered areas

- - Hydraulically removes sediment from barges filled at other location

-

Barges / scows


- - Can be loaded or unloaded bottom placement

300 – 4, 000 / week

Spider / Bardge


- - Loads barges from hydraulic dredge

-

Pipeline Sensitive to wave action and strong currents

- - Land pipeline offers flexibility for material placement

-

Booster pump stations

- - - Use when insufficient power of main pump for pumping material long distances

-

Fixed systems - - - Permanent pump stations set in sand traps

-

Trucks - - - Economic only if distance is short and quantity is small and if roads are available to beach

50, 000 / week

Chapter 8 DREDGER

8-8 March 2009

8.4 EQUIPMENT OF DREDGER Typical Dredger Components are: a) Dredge Construction i) Hull / Pontoon ii) Cabin Room iii) Engine Room iv) Store Room v) Mess Room vi) Water Tanks vii) Fuel Tanks

b) Cutting, spud and winch system i) Cutter - Cutter Motor - Cutter Head - Cutter teeth ii) Spud - Spud - Spud guides iii) Winch - Ladder winch - Swing wire

c) Hydraulics System i) Hydraulics pumps ii) Hydraulics motor

d) Electrical System i) Generator ii) Switchboard iii) Dredge Control System

e) Engines i) Auxiliary engines ii) Main engines - Fuel oil system - Lubricator oil system - Grease system - Gland flushing system - Cooling water system - Exhaust gas system - Hydraulics system iii) Gearbox

Chapter 8 DREDGER

March 2009 8-9

f) Suctions and Discharge system i) Dredge pump ii) Suction dredge pump iii) Gland pump iv) Flushing pump v) Floating pipelines 8.5 DISPOSAL OF MATERIALS In a "hopper dredger", the dredgings end up in a big onboard hold called a "hopper", which has doors in its bottom. The excess water in the dredgings is spilled off by sedimentation: as the mud and sand settle to the bottom of the hopper, the water is siphoned from the top and returned to the sea to reduce weight and increase the amount of dredgings that can be carried in one load. When the hopper is full, the dredger stops dredging and sails to a dump site and opens the bottom hopper doors, dumping the slurry out. Or the hopper can be emptied from above. Sometimes with a suction dredger the slurry of dredgings and water is pumped straight into pipes which deposit it on nearby land by pipes; or in barges (also called scows) which deposit it in the deep sea or on land. Dredged materials will be disposed of at either one of the following locations: a) At a temporary basin with adequate storage capacity outside the limits of the existing approach

channel. b) At a temporary stockpile within 1 nautical mile outside of the end of the existing approach channel. c) At the contractual spoil disposal area d) At an alternative spoil disposal area

Chapter 8 DREDGER

8-10 March 2009

Table 8.3 - Disposal Systems

Dredge type Disposal Method Comments

Hopper dredger (THD)

Sea dumping, shore pumping, rain bowing, booster station, submerged pipeline

Maintenance/capital dredging of widening and deepening of port channels, beach/sea wall nourishment and land reclamation

Hopper dredger (THD)

Hopper dredger combined with cutter suction – double handling, submerged pipelines

Maintenance/capital dredging of widening and deepening of port channels, beach/sea wall nourishment and land reclamation

Cutter suction pipeline dredger (CSD)

Spider barge, hopper barge, hydraulic unloading and dredge pipelines

Capital dredging of port channels, harbour berths, land reclamation, beach and coastal restoration

Cutter suction pipeline dredger (CSD)

Hopper barge and second cutter suction pipeline dredger with submerged pipelines

New port projects under capital dredging

Mechanical clam shell dredger

Hopper barge and hydraulic unloader with submerged pipelines

Offshore location operations

Desiltation and water jetting plants

Displacement of silt through pipelines or travel through tidal waves

Environmantal effects and siltation near the harbour berths

Excavators, grab dredgers and bucket suction dredgers

Barge/truck loading, beach and sea walls nourishment

Construction of jetty, bunds, roads/buildings and other earth works on shore

Environmental impacts: Dredging can create disturbance to aquatic ecosystems, often with adverse impacts. In addition, dredge spoils may contain toxic chemicals that may have an adverse effect on the disposal area; furthermore, the process of dredging often dislodges chemicals residing in benthic substrates and injects them into the water column. The activity of dredging can create the following principal impacts to the environment:

• Release of toxic chemicals (including heavy metals and PCB{polychlorinated biphenyls}) from bottom sediments into the water column.

• Short term increases in turbidity, which can affect aquatic species metabolism and interfere with spawning.

• Secondary effects from water column contamination of uptake of heavy metals, DDT{Dichloro-Diphenyl-Trichloroethane} and other persistent organic toxins, via food chain uptake and subsequent concentrations of these toxins in higher organisms including humans.

• Secondary impacts to marsh productivity from sedimentation. • Tertiary impacts to avifauna which may prey upon contaminated aquatic organisms. • Secondary impacts to aquatic and benthic organisms' metabolism and mortality. • Possible contamination of dredge spoils sites.

Chapter 8 DREDGER

March 2009 8-11

8.6 METHOD OF MEASUREMENT AND PAYMENT

Table 8.4 Cost Worksheet - Built Up Rates for Dredging Works

TERM CALCULATION PARAMETERS CALCULATION AMOUNT 1.0 DREDGING VOLUME

Channel-1 Channel-2 Basin-1 Basin-2 Sub-Total Allow for overdredging 12% Total Vol. Of Dredging - Cu.M

Cu.m Cu.m Cu.m Cu.m Cu.m Cu.m Cu.m

2.0 DREDGER - CUTTER SUCTION DREDGER (CSD) With assumption that the dredge materials (sand) 100% suitable to be used for beach filling and the areas of beach filling not more than 2 Km from the dredging works. Dredger Specification IHC Beaver 5014C (MMDC - 1)- Cutter Suction Dredger (CSD) Length overall, ladder rise - 35.10 m Breadth, moulded - 9.50m Depth, moulded – 2.46m Mean Draught with full bunkers – 1.5 m Total installed power – 1484 hp (1,091 kW) Dredge pump power at shaft – 938 hp (690 kW)

Estimated Cost ot Dredger Charter Rate Operational - Rate per day Charter Rate Standby - Rate per day Cost of Operation: Dredger Operating Cost @ Rate ___ (RM/day) Dredger Standby Cost @ Rate ___ (RM/day) Crew Cost @ Rate ___ (RM/month) Fuel cost @ ___ (RM/litre)

based on monthly rental (26days) 70%of opr. Rate 26 days x Rate 4 days x Rate Rate ___ litres X Rate

RM RM RM RM RM RM

Dredger Operating Cost Per Month Rate of Dredging Vol. Per Month @ output ___(Cu.m/hr)

Sub -total Output(Cu.m/hr) x 16hr x 26days/mth

RM RM

a. Dredger Cost / m3 RM

3.0 3.1

Dredging Facilities Work Boat - Rental & Operation Operation @ Rate ___ (RM/day) Standby @ Rate ___ (RM/day) Crew @ Rate ___ (RM/month) Fuel cost @ ___ (RM/litre)

26 days x Rate 4 days x Rate Rate ___ litres X Rate Sub-Total

RM RM RM RM RM

b. Work Boat Cost / m3 RM

Chapter 8 DREDGER

8-12 March 2009

3.2 Speed Boat - Rental & Operation

Rental and Operational Rate Per Month @ Rate ____ (RM/day)

Rate x 26 day/mth

RM

c. Speed Boat Cost / m3 RM

3.3 Floating Pipe - Wear & Tear Total length of pipe req. - 1 ,300m Total cost of pipe @ Rate____(RM/meter length) Life span of pipe - 1 million cu.m

Rate x 1300 m RM

d Floating Pipe Cost / m3 RM 3.4 Floater For Floating Pipe - Wear & Tear

Total no. of floater req. @ 1,300m/12 =100 Nos Total cost of floater - Rate____(RM/unit) Life span of floater - 10 million cu.m

Rate x 100nos RM

e Floater Cost / m3 RM 3.5 Rubber Hose (Jointing Floating Pipe) - Wear &

Tear Total no. of rubber hose req. @ 1,300/12 =100 Nos Total cost of rubber hose - Rate____(RM/unit) Life span of rubber horse - 2.0 million cu.m

Rate x 100 nos * RM

f Rubber Hose Cost / m3 RM 3.6 Other Facilities - Rental & Operation

Welding Set - 2 Nos @ Rate____(RM/mth) Generator Set - 2 No= @ Rate____(RM/mth) Workshop Cabin & Store @ Rate____(RM/mth) Welder - 2 Person @ Rate____(RM/mth)

2Nos x monthly rate 2 Nos X monthly rate monthly rate 2 x rate X 1.4 x 100%

RM RM RM RM

Sub -total RM g Other Facilities Cost/m3 RM 4.0

Supervision Cost For Dredging Works Project Manager- 1 Person @ Rate____(RM/mth) Site Engineer - 1 Person @ Rate____(RM/mth) Site Supervisor - 4 Person@ Rate____(RM/mth) Lab. Assistant - 1 Person @ Rate____(RM/mth) Accomodation - 2 Nos x monthly rate Transportation - 2 Nos x monthly rate Others Miscellaneous @ Rate____(RM/mth)

1 x rate. x 1.7 x 70% 1 x rate.x1.7 4 x rate x 1.4x100% 1x rate x 1.4 x 100% Rate rate rate Sum

RM RM RM RM RM RM RM

Sub -total RM Supervision Cost / m3 RM Rate of Dredging Cost / Cu.M - ( sum a - g & 4.0

) Allow during 1 month of idling time due weather conditions - Add 4% Allow for 15% Profit

RM RM RM

Rate For Dredging Works Per Cu.M RM

Chapter 8 DREDGER

March 2009 8-13

8.7 BUILT UP RATES FOR FILLING & PROFILING WORKS

Table 8.5 - Built Up Rates for Filling & Profiling Works TERM CALCULATION PARAMETERS CALCULATION AMOUNT 1.0 Filling and Profiling Works

Assumption - all the dredged materials from the river mouth is suitable for beach filling & profiling works. Total Vol. of Filling For Filling & Profiling Works (Cu.M): Excluding over dredge including over dredge 15%

Cu.m Cu.m

2.0 2.1

Filling and Levelling Works Equipments Effective Filling rate per month -(Cu.M) Land Base Pipeline System Total length of pipe req. - 1,000m Total cost of pipe - @ Rate____(RM/mth) Pipe jointing and accesssones Life span of pipe - 1 million cu.m Land Base Pipeline Cost Per Month

hr. output. x I6hr. x 26days/mth Rate x 1000m Lump sump

Cu.m RM RM RM

a Land Base Pipeline Cost / m3 RM 2.2 Machineries & Equipment Land Base Bull Dozer - 3 Nos @ Rate____(RM/mth)

Fuel cost @ Rate____(RM/litre)

3 Nos x rate x 24hrs x 26days 3 Nos x 18lit/hr x 24hrs x 26days x rate

RM RM

Excavator - 2 Nos @RM NA/hr Fuel cost @ Rate____(RM/litre)

2 Nos x rate x 24hrs x 26days 2 Nos x18lit./hrx 24hrs x 26days x rate

RM RM

Wheel Loader - 1 Nos @RM NA/hr Fuel cost @ Rate____(RM/litre)

1 Nos x rate x 24hrs x 26days 1 Nos x 18lit/hr x 24hrs x 26days x rate

RM RM

Generator Set - 2 No @RM NA/mth (20Kw) Fuel cost @ Rate____(RM/litre)

2 Nos x rate 2 Nos x 10 lit/hr x 12hrs x26days x rate

RM RM

Welding Set - 1 No @RM NA/mth Fuel cost @ Rate____(RM/litre)

1 Nos x rate 1 Nos x 5lit/hr x 10hrs x 25days x rate

RM RM

Dump Truck- 3 Nos @RMNA/hr (15 tonne) Fuel cost @ Rate____(RM/litre)

3Nos x rate x 10hrs x 26days 3 Nos x 10lit/hr x 12hrs x 26days x rate

RM RM

Fuel Tank - 10,000 lit Capacity -Rental monthly

sum RM

RM b Machineries & Equip. Cost / m3 RM

Chapter 8 DREDGER

8-14 March 2009

3.0

Supervision Cost Project Manager - 1 Person @ Rate____(RM/mth) Site Engineer - 1 Person @ Rate____(RM/mth) Site Supervisor - 2 Person @ Rate____(RM/mth) Accomodation - 2 Nos @ Rate____(RM/mth) Transportation - 2 Nos @ Rate____(RM/mth) Others Miscellenous

1x rate x 1.7x30% 1 x rate x 1.7 2 x rate x 1.4 2Nos x rate 2 Nos x rate Sum

RM RM RM RM RM RM RM

c Supervision Cost/m3 RM 4.0 Labour Cost Skill Labour - 3 Persons @ Rate____(RM/hr)

Unskill Labour - 10 Persons @ Rate____(RM/hr) Welder - 2 Persons @ Rate____(RM/hr) Accomodation - 4 Nos @ Rate____(RM/mth) Transportation - 1 Nos @ Rate____(RM/mth)

3 x rate x 12hrs x 26 x 1.4 10 x rate x 12hrs x 26 x 1.4 2 x rate x 12hrs x 26 x 1.4 4 x rate 1 Nos x rate

RM RM RM RM RM RM

d Labour Cost /m3 RM Rate of Beach Filling & Profiling Works / Cu.M

( sum a-d) Allow for 15% Profit

RM RM

Rate For Filling & Profiling Works Per Cu.M (RM)

RM

Chapter 8 DREDGER

March 2009 8-15

8.8 ORGANISATION AND RESPONSIBILITY The Works Manager has overall responsibility for the execution of the dredging and reclamation works. He reports directly to the Project Manager. Superintendents will supervise the dredgers employed, including their auxiliary equipment (if applicable), during the execution of the dredging works. The Superintendents, in co-operation with the Dredge Masters, co-ordinate the daily execution of the dredging works. Superintendents report directly to the Works Manager. Furthermore Technical Managers will be responsible for the condition and maintenance of the dredgers involved, including their auxiliary equipment (if applicable). These Technical Managers are not necessarily stationed at the work site, but will in some cases operate from the branch offices of the Dredge Owners. Technical Managers report directly to the Works Manager. Besides the Owner Technical Managers described above there is also a Technical Manager who works directly for the Joint Venture. He is responsible for the condition and maintenance of all auxiliary and other equipment on site. He also reports directly to the Works Manager. The Chief Surveyor is responsible for the execution of all survey works involved. He reports directly to the Works Manager. Junior surveyors assist the Chief Surveyor. They report directly to the Chief Surveyor. On board the dredgers the Masters have the overall responsibility. They manage and organize everyday work and life on board. Their primary aim is to ensure that the works to be performed are executed in a safe and efficient manner. The Masters report directly to the Superintendents. However, on board the dredgers the Masters are the highest authority. They have the overall nautical and safety responsibility on board. For the execution of nautical and dredging tasks the Masters are assisted by their ships officers. Ships officers are well trained and are authorized to work independently during their watch on the bridge. They are capable of executing and supervising tasks as ordered by the Masters. Chief Engineers are responsible for the safe and efficient deployment of all mechanical equipment on board. They report directly to the masters and are assisted by engineers in order to maintain all equipment on board the dredgers in good operational order. 8.9 COMPETENCY “Dredge” means any floating structure used for the winning of tin ore, for the dredging of rivers and waterways or for purposes of land reclamation, and includes the bucket type dredge and the cutter-suction type dredge.

“Dredgemaster” means a person who holds a dredge master’s certificate of competency issued under Section 30 Factories and Machinery Act. “Visiting Engineer” means the holder of an engineer’s certificate of competency for internal combustion engines who is employed by an owner to make periodical visits to , and inspections of, his machinery. i. Where the greatest horse-power of any one internal combustion engine in any one installation is

not greater than one hundred, a first or second grade driver shall be in charge during each shift.

Chapter 8 DREDGER

8-16 March 2009

ii. Where there is more than one internal combustion engine in the installation, the driver in charge

shall be assisted during each shift by such other first or second grade drivers as shall ensure that including the driver in charge, there are not more than two engines to each driver.

iii. Where the greatest horsepower of any one internal combustion engine in any one installation is

greater than one hundred but not greater than five hundred, a first grade driver shall be in charge during each shift and where there is more than one internal combustion engine in the installation the provisions of paragraph (ii) shall apply.

iv. Where the greatest horsepower of any one internal combustion engine in any one installation is

greater than five hundred but not greater than five thousand, a first grade driver shall be in charge during each shift and where there is more than one internal combustion engine in the installation, the driver in charge shall be assisted during each shift by such other first grade drivers as shall ensure that, including the driver in charge there are not more than two engines to each driver. In addition, the owner shall employ a first grade visiting engineer.

v. Where the greatest horsepower of any one internal combustion engine in any one installation is

greater than one thousand but does not exceed one thousand five hundred , a first or second grade engineer shall be in charge and he shall be assisted during each shift by a first grade driver and where there is more than one internal combustion engine in the installation such other first grade drivers shall be employed sufficient to ensure that there are not more than two engines to each driver during each shift.

vi. Where the greatest horsepower of any one internal combustion engine in any one installation is

greater than one thousand five hundred, a first grade engineer shall be in charge and he shall be assisted during each shift by a first grade driver and where there is more than one internal combustion engine in the installation, such other first grade drivers shall be employed sufficient to ensure that there are not more than two engines to each driver during each shift.

A dredge driven by steam power shall be in the charge of a person who holds:

a) An engineer’s (steam) certificate of competency , such person having served for a period of not less than six months as an assistant in charge of a shift on a dredge and had such certificate endorsed accordingly ; or b) A dredgemaster’s (steam and electric) certificate of competency.

A dredge driven by electric power generated by internal combustion engines installed on the dredge or directly by internal combustion engines shall be under the charge of a person who holds:-

a) An engineer’s (internal combustion engines) certificate of competency , such person having served for a period of not less than six months as an assistant in charge of a shift on a dredge , and had such certificate endorsed accordingly ; or b) A dredgemaster’s (internal combustion engines and electric) certificate of competency.

A dredge driven by electric power from bulk supply shall be under the charge of a person who holds:- a) An engineer’s (steam) or an engineer’s (internal combustion engines) certificate of

competency , such person having served for a period of not less than six months as an assistant in charge of a shift on a dredge , and had such certificate endorsed accordingly.

b) A dredgemaster’s certificate of competency.

Chapter 8 DREDGER

March 2009 8-17

An engineer or dredgemaster in charge of a dredge shall be assisted during each shift by first or second grade drivers (steam) or first or second grade drivers (internal combustion engines) as appropriate in accordance with the provisions of regulation 5 or 6 Factories and Machinery Act. 8.10 SAFETY Dredgers and Other Floating Plant Safety Plan

A safety plan (with a map of the ship) must be available on board and placed where the crew can easily see it.

The Captain/Senior Dredge Master shall familiarize the crew with this safety plan. The plan must also indicate the mustering points in case of emergencies.

Inspection of life-saving and safety equipment

The Captain/Senior Dredge Master must regularly (monthly) organize an inspection of all life-saving and safety equipment, according to the list contained in the safety plan, and take corrective action as appropriate.

Watertight Doors (W.T.)

W.T. doors shall be regularly inspected on closing. W.T. doors to watertight bulkheads must be closed when navigating at sea and in estuaries. W.T. doors to accommodation, deck houses, etc. on the weather-deck must be closed in

heavy weather and when there is a possibility that water may seep into spaces below the weather-deck.

The power-actuated W.T. doors controlled from the bridge would normally be kept open. A warning system which indicates when these doors are being closed or are closed must be in situ.

Engine rooms , workshops , pump rooms

The senior supervisor will make sure that, before any guard is removed the power is shut off and the machine is isolated. After repairs or adjustments have been carried out he will personally see that the guards are replaced securely before the machinery is restarted.

Steel wires / ropes

Steel deck wires must be protected as much as possible against the whiplash effect that occurs should the wires part.

You should not in any circumstances stand in a loop of rope or wire, nor if you can avoid it, in the loop formed between the mooring winch and the coiled rope.

Never stand in the vicinity of a rope or wire that is under strain or being worked. When ropes and wires are being subjected to exceptional strain, eg. When towing, keep well

clear in case a rope parts. Install grating behind the tow hook for protection of the wheelhouse. When using slip wires for mooring to buoys or dolphins, never put the eyes of the wire over

the bollards. The eyes of the wires should be wound round to prevent them catching on obstructions

when they are released. Always make sure that warping ends on winches are free from grease and paint and that

rollers, etc. turn smoothly. Examine a rope frequently throughout its length for both external wear and for wear

between the strands, in order to assess its residual strength. Always assess the strength of the entire rope on the basis of the most damaged part of the

rope. Remember, ‘a chain is as strong as its weakest link’.

Chapter 8 DREDGER

8-18 March 2009

Synthetic ropes are, when they break, extremely dangerous. Always treat them with extreme

caution. Excessive wear of synthetic ropes is shown by a high degree of powdering between the strands, giving a clear indication that the rope has been overtaxed and that its strength is impaired.

Ensure that :

• Wires and ropes can move freely and cannot hook behind any obstacle; • When connecting two steel wires, both wires are either left or right hand laid; • Free ends of wires are whipped; • Wire rope clips attached with U-bolts have the U-bolts on the dead or short end of

the wire; the clip nuts must be retightened at frequent intervals; U-bolts must never be used for lifting wires or slings.

Pay special attention to all kind of steel wires on board floating plant to ensure that there are

free from the following defects:

• Kinks; • Frayed strands; • Knots; • Crushed parts; • Extreme rust; • Fractures; • Snags; • Damaged end connections.

Wires with the above-mentioned defects must be replaced and subsequently rendered useless.

Safety guards over wires have to be fitted where necessary and possible. Ensure that wires and ropes are regularly inspected and that the inspection record/date is

clearly visible on the equipment by using colour, label or date. All new ropes, chains and slings purchased shall be accompanied with certificates.

Access ways

Ensure that the under-mentioned access ways are free from obstacles , grease , oil and mud:

• Passage ways; • Walkways; • Workshops floors; • Platforms; • Staircases (ways); • Gangways; • Scaffolding.

Soundings

The Captain/Senior Dredge Master must ensure that all compartments and buoyancy tanks, including fore- and after-peaks, are sounded daily/weekly, recorded in the logbook, and passed on to the Chief Engineer, for recording in the engine logbook.

Ballast Tanks

Ballast tanks must not be filled or emptied without prior permission from the Captain/Senior Dredge Master.

Chapter 8 DREDGER

March 2009 8-19

Fuel Tanks

Fuel tanks must be marked in order to warn people that naked flames and heat are dangerous.

Engine exhausts in the vicinity must be provided with spark arrestors. Hatches and tank inlets (openings)

Hatches and tank inlets have to be marked and when open they must be cordoned off. All hinged hatch covers have to be secured against falling back.

Entry into tanks and enclosed areas

A tank or other confined spaces must only be entered if one is certain that it is gas free and contains sufficient oxygen. If possible this check has to be carried out by an expert (gas doctor).

Various safety and precautionary measures The following components must be freely accessible and in good working order :

• Valves and non-return valves in bilge lines; • Fire flaps in ventilation shafts; • Emergency stops on winches and the like; • Quick release valves; • Watertight doors and hatches.

Floating pipelines

Before starting work on/or inspecting a floating pipeline , ensure the following safety precautions are taken :

• Inform the Dredge Master or Pipeman and when necessary to stop the pumps; • A work boat is in attendance; • The inspector must wear a life jacket or a survival suit (depending on the

circumstances); • On the work boat someone must standby with a life buoy and line; • Inspections are preferably carried out during day light hours.

Floating pipelines shall not be used as a way of access to the vessel unless equipped with walkways with handrails.

8.11 OPERATIONAL TRAINING The training package for the operators is such that, after the completion of the training, the operators will have a thorough understanding of the principles of operation of each of the dredging components and their interaction. They will be able to start-up the dredge after every major shutdown/ overhaul of the dredge. The package shall, among others, include the following: a) General introduction to dredging. b) General construction & operation of dredge pumps. c) General construction & operation of dredge cutter systems. d) General construction & operation of spud/ spud carriage (spud system). e) Operation of winches f) Operation of ladder g) Instrumentation and control philosophy operation of the automation system h) Operation of diesel engines and diesel generator set. i) Start-up procedure for the dredge inclusive of support/auxiliary facilities of the Dredge j) Operating philosophy of the hydraulic system. k) Troubleshooting

Chapter 8 DREDGER

8-20 March 2009

8.12 OPERATION & MAINTENANCE Manuals shall cover the following procedures: a) Normal start-up procedure b) Normal shut-down procedure c) Emergency shutdown procedure d) Special procedure e) Temporary procedure f) Equipment preparation procedure g) Interlocks between the systems 8.13 MAINTENANCE TRAINING The training package related to maintenance of the dredge components shall, among others, include the following, to enable the maintenance crew (Mechanical, Electrical & Instrumentation to operate safely, reliably and economically: a) List components that are most commonly subjected to severe wear & tear, high vibration, erosion,

corrosion and fracture (NATURAL FAULTS). b) Preventive Maintenance program for dredge components. c) Predictive Maintenance program for dredge components. d) Trouble shooting chart for each dredge components. e) Exploded view with part numbers of the dredge components (reference can be made to

manufacturer's drawings/ instructions). f) Maintenance schedule for each dredge item indicating various components of an item, procedure,

tick maintenance requirement of daily/ weekly/ monthly /quarterly/ annually, remarks. 8.14 SAMPLE OPERATING PROCEDURES Operating principle a) Cutterhead and dredge pump. The cutter suction dredger is the most common of all dredger types. The two main components are cutterhead and the dredge pump. The cutterhead, attached to the entrance of the suction pipe, agitates or cuts the soil material for subsequent removal by the dredge pump. The dredge pump creates a vacuum in the suction pipe and draws up the dredged material through the pump. b) Foward movement (see simplified cutter diagram). When in operation, the cutter suction dredger makes use of two (2) spuds which are mounted on both sides of the stern corners, viz port spud and starboard spud. Initially, the port spud is up while the starboard spud is down. When the dredger starts to swing to the starboard in an arc, it pivots on the starboard spud. At the end of the swing, the port spud is dropped and the starboard spud is raised before a swing to the port. Thus the dredger advances by interchanging of the two spuds at the end of the swing operation. c) Operation cycle. A so-called "cut" is the dredging action while the dredger is swinging on a digging spud until the required depth has been reached. When the spuds are repositioned, a new swinging action can be made. Then the lifted spud (being ahead of the other.) is dropped and the grounded spud is lifted which action is called "step on spuds".

Chapter 8 DREDGER

March 2009 8-21

When the sideline wire rope come in an negative angle with the main line of the cutter, the swing anchors need to be repositioned. These activities form a subcycle: • cut - step on spuds - cut - step on spuds (repeat as necessary) • Reposition sideline swing anchors. The complete operation cycle consists of repeated subcycles as many times as necessary and then changing pipeline position. The pumping process is continuous, but during stepping the cutter head is running without cutting.

Fig. 8.6 Simplified Cutter Diagram 8.15 SAMPLE MAINTENANCE CHECKLIST a) Daily pre-start checklist • Visually inspect all the hoses (water, fuel and hydraulic) for leaks or other damage. • Make sure that fuel lines are properly clamped and tight. Check for loose fittings or leaks. • Check for any obvious cooling water leaks or loose connections. Inspect the pump for evidence of leaks. • Check for lubrication leaks, such as the front- and rear crankshaft seals, crankcase, oil filter, oil

gallery plugs and sensors, and valve covers. • Check the oil level for the cutter motor bearing at the tank on the operating cabin. • Check the oil level in the hydraulic tank and refill if necessary. • Lubricate all the sheaves, turning points and ball joints daily. • Visually check of the engine and make repairs if necessary. • All guards must be present. Replace any guards that are damaged or missing. b) Weekly pre-start checklist • Check the levels of all the tanks and trim the ship horizontally (if necessary). • Check the sea water inlet filter(s), if necessary remove any dirt from the baskets. • Check if the air inlet piping and filters are in place and clean. • Check all the hydraulic filters and clean or replace if necessary. • Visually inspect all the pipe lines (water, fuel and hydraulic) for leaks, rust or other damage. • Check the levels of all the batteries and refill with distilled water if necessary. • Check the drinking water level. • Check the oil level of all the engine and refill if necessary and check the control glass level of the

regulator. • Check the oil level of the dredge pump gear box. • Check the oil level of the other gearbox (es).

Chapter 8 DREDGER

8-22 March 2009

• Check the levels of the cooling water system on the sight glasses of the expansion tanks if

necessary fill it up with water (half level in cold condition),however with a certain percentage of anti freeze

• Check the Gasoline level in the wing tanks. • Check the level of the dirty oil tanks and if necessary discharge them. • Check visual all the V- belts (gland- & flushing pump, main generator). • Visual inspection of the cutter head. • Check electrical cables and the battery for poor connections and corrosion.

CHAPTER 9 ASSET MANAGEMENT

Chapter 9 ASSET MANAGEMENT

March 2009 9-i

Table of Contents


List of Tables ........................................................................................................................ 9-iv

List of Figures ....................................................................................................................... 9-iv

9.1 INTRODUCTION .......................................................................................................... 9-1

9.2 ARAHAN PERBENDAHARAAN ........................................................................................ 9-1

9.2.1 Latar belakang .............................................................................................. 9-1

9.2.2 Siapa yang tertakluk kepada Arahan Perbendaharaan? ..................................... 9-2

9.2.3 Apakah pengubahsuaian / pengemaskinian yang telah dilakukan ? .................... 9-2

9.2.5 Pengenalan kepada bab B : Tatacara perakaunan ............................................ 9-3

9.2.6 Pengenalan kepada bab C : Audit, kehilangan dan tatacara hapus kira .............. 9-3

9.3 PROCEDURE FOR GOVERNMENTS DEPARTMENT............................................................ 9-4

9.3.1 Peranan dan tanggungjawab pegawai pengawal .............................................. 9-4

9.3.2 Tugas dan tanggungjawab unit pengurusan aset ............................................ 9-5

9.3.3 Penguatkuasaan ........................................................................................... 9-5

9.3.4 Pelaksanaan ................................................................................................. 9-5

9.3.5 Pembatalan .................................................................................................. 9-5

9.3.6 Pemakaian ................................................................................................... 9-6

9.4 TATACARA PENGURUSAN ASET(TPA) ............................................................................ 9-6

9.4.1 Pendahuluan ................................................................................................ 9-6

9.4.1.1 Definisi aset ................................................................................. 9-6

9.4.1.2 Definisi aset alih ........................................................................... 9-6

9.4.1.3 Harta modal ................................................................................. 9-7

9.4.1.4 Inventori ...................................................................................... 9-7

9.4.1.5 Kategori harta modal .................................................................... 9-7

9.4.1.6 Kategori inventori ......................................................................... 9-7

9.4.2 Bab A – Penerimaan ...................................................................................... 9-7

9.4.3 Bab B ......................................................................................................... 9-10

9.4.3.1 Pendaftaran ............................................................................... 9-10

9.4.3.2 Objectif pendaftaran ................................................................... 9-10

9.4.3.3 Tempoh mendaftar ..................................................................... 9-10

9.4.3.4 Pendaftaran aset hadiah .............................................................. 9-10

9.4.3.5 Pendaftaran aset lucuthak ........................................................... 9-10

9.4.3.6 Punca maklumat ......................................................................... 9-11

9.4.3.7 Dokumen pendaftaran ................................................................. 9-11

9.4.3.8 Carta aliran dan proses kerja pendaftaran ..................................... 9-14


9-ii March 2009

9.4.4 Bab C – Penggunaan, penyimpanan dan pemeriksaan .................................... 9-16

9.4.4.1 Objektif penggunaan, penyimpanan dan pemeriksaan .................... 9-16

9.4.4.2 Penggunaan ............................................................................... 9-16

9.4.4.3 Penyimpanan ............................................................................. 9-16

9.4.4.4 Pemeriksaan ............................................................................... 9-16

9.4.5 Bab E – Pelupusan ...................................................................................... 9-17

9.4.5.1 Definisi pelupusan ....................................................................... 9-17

9.4.5.2 Objektif pelupusan ...................................................................... 9-17

9.4.5.3 Justifikasi pelupusan ................................................................... 9-17

9.4.5.4 Kuasa melulus pelupusan ............................................................ 9-17

9.4.5.5 Kuasa melulus perbendaharaan.................................................... 9-17

9.4.5.6 Kuasa melulus kementerian/jabatan ............................................. 9-18

9.4.5.7 Unit pengurusan aset kementerian/jabatan ................................... 9-18

9.4.5.8 Pelantikan lembaga pemeriksa ..................................................... 9-18

9.4.5.9 Keanggotaan lembaga pemeriksa ................................................. 9-18

9.4.5.10 Tugas lembaga pemeriksa ........................................................... 9-18

9.4.5.11 Urus setia pelupusan ................................................................... 9-18

9.4.5.12 Kaedah pelupusan ...................................................................... 9-19

9.4.5.13 Tender ....................................................................................... 9-19

9.4.5.14 Sebut harga ............................................................................... 9-20

9.4.5.15 Lelong ....................................................................................... 9-20

9.4.5.16 Jualan sisa ................................................................................. 9-20

9.4.5.17 Tukar barang (Barter trade) ......................................................... 9-21

9.4.5.18 Tukar beli (Trade in) ................................................................... 9-21

9.4.5.19 Tukar ganti (Cannibalize) ............................................................. 9-21

9.4.5.20 Pindahan .................................................................................... 9-22

9.4.5.21 Hadiah ....................................................................................... 9-22

9.4.5.22 Musnah ...................................................................................... 9-22

9.4.5.23 Pelupusan melalui kontrak pusat .................................................. 9-23

9.4.5.24 Tindakan semasa melaksanakan pelupusan ................................... 9-23

9.4.5.24 Carta aliran dan proses kerja ....................................................... 9-24

9.4.6 Bab F ......................................................................................................... 9-26

9.4.6.1 Kehilangan dan hapus kira ........................................................... 9-26

9.4.6.2 Tafsiran kehilangan ..................................................................... 9-26

9.4.6.3 Tafsiran hapus kira ..................................................................... 9-26

9.4.6.4 Kuasa melulus hapus kira ............................................................ 9-26


March 2009 9-iii

9.4.6.5 Kuasa melulus peringkat perbendaharaan ..................................... 9-26

9.4.6.6 Kuasa melulus peringkat pegawai pengawal .................................. 9-27

9.4.6.7 Urusetia kehilangan dan hapus kira .............................................. 9-27

9.4.6.8 Tugas ........................................................................................ 9-27

9.4.6.9 Proses hapus kira ....................................................................... 9-27

9.4.6.10 Carta aliran dan proses kerja ....................................................... 9-28


9-iv March 2009

List of Tables

Table

Description Page

9.1

9.2

9.3

9.4

9.5

9.6

Carta Aliran Pendaftaran Aset Alih Kerajaan Di Peringkat Kementerian/Jabatan/PT

Proses Kerja Pendaftaran Aset Alih Kerajaan

Carta Aliran Pelupusan Aset Alih

Proses Kerja Pelupusan Aset Alih Kerajaan

Carta Aliran Hapus Kira Aset

Proses Kerja Hapus Kira Aset Alih Kerajaan

9-14

9-15

9-24

9-25

9-28

9-29

List of Figures

Figure

Description Page

9.1

9.2

9.3

9.4

9.5

9.6

Carta Aliran untuk Tatacara Pengurusan Aset(TPA)

KEW.PA-1 - Borang Laporan Penerimaan Aset

Carta Aliran untuk Pendaftaran Aset

KEW.PA-2 - Daftar Harta Modal

KEW.PA-3 - Daftar Inventori

Carta Aliran untuk Kehilangan dan Hapus Kira

9-6

9-9

9-10

9-12

9-13

9-26


March 2009 9-1

9 ASSET MANAGEMENT

9.1 INTRODUCTION This paper, in Bahasa Malaysia, is only applicable to DID departmental staff only, it is extracted from the current Government Treasury Cicular, [Arahan Perbendaharaan (Semakan 1997)], Asset Management Procedure [Tatacara Pengurusan Aset] , on the proper procedures to receive, register, safekeeping, use, maintain, write off and disposal of government property. Please take note that the Circular may be reviewed, amended or (partially or totally) replaced from time to time. This manual shall thus be used as a general guide by the departmental staff only. The procedure under the latest circular shall be used in the actual execution of asset management work. The officer in charge of any asset management shall also refer to the official delegation of power from the Federal Financial Controlling Officer to the federal departmental (DID) officers in the head office/project office OR State Financial Controlling Officer to the state departmental (DID) officer, so that the officers will carry out their duties within the limits of authority delegated to each departmental officer. 9.2 ARAHAN PERBENDAHARAAN 9.2.1 Latar belakang Arahan Perbendaharaan (AP) dikeluarkan mengikut keperluan Seksyen 4 Akta Tatacara Kewangan 1957 yang memperuntukkan bahawa: "Tiap-tiap pegawai perakaunan adalah tertakluk kepada Akta ini dan hendaklah menjalankan apa-apa kewajipan, menyenggara buku-buku dan menyediakan akaun-akaun yang ditetapkan oleh atau di bawah Akta ini atau oleh arahan-arahan yang dikeluarkan oleh Perbendaharaan mengenai perkara tatacara kewangan dan perakaunan yang tidak bertentangan dengannya: Dengan syarat bahawa seseorang pegawai perakaunan Negeri adalah di samping itu tertakluk kepada apa-apa arahan Pihak Berkuasa Kewangan Negeri yang tidak bertentangan dengan yang tersebut di atas". AP merupakan peraturan kewangan dan perakaunan utama dalam pengurusan kewangan Kerajaan. Ianya mengandungi arahan-arahan mengenai pengurusan belanjawan, hasil, perbelanjaan, perolehan, pengurusan aset dan pelupusan. AP yang digunapakai sekarang ialah AP yang telah disemak kali pertama selepas tahun 1970 yang mula berkuat kuasa pada 29 Disember 1997. Semakan pada tahun 1997 telah mengambil kira perubahan-perubahan dalam sistem pengurusan kewangan dan perakaunan yang berlaku semenjak tahun 1970, seperti pengubahsuaian dalam sistem perakaunan, penggunaan komputer dan pelaksanaan Sistem Belanjawan Program dan Prestasi. Walau bagaimanapun, perubahan-perubahan telah semakin pesat berlaku selepas tahun 1997 terutama ke atas pengubahsuaian dalam sistem perakaunan yang menggunakan sistem komputer dan automasi pejabat selaras dengan pelaksanaan Kerajaan Elektronik. Sehubungan dengan itu Perbendaharaan telah membuat semakan semula ke atas AP untuk kali kedua supaya selaras dengan pelaksanaan Kerajaan Elektronik, di samping mengemaskini dengan AP yang dikeluarkan dari semasa ke semasa melalui Pekeliling Perbendaharaan semenjak tahun 1997 dan pengemaskinian penggunaan istilah yang betul. Draf akhir semakan semula AP (untuk kali ke dua) yang diluluskan oleh Jawatankuasa Induk Semakan Semula AP telah dihantar kepada Bahagian Gubalan, Jabatan Peguam Negara untuk tujuan semakan dari segi gubalan dan bahasa.


9-2 March 2009

9.2.2 Siapa yang tertakluk kepada Arahan Perbendaharaan? Seksyen 4 Akta Tatacara Kewangan 1957 memperuntukkan bahawa tiap-tiap pegawai perakaunan adalah tertakluk kepada Arahan Perbendaharaan, mengenai tatacara kewangan dan perakaunan termasuk tatacara bagi memungut, menyimpan dan membayar wang awam Persekutuan dan Negeri, bagi membeli, menyimpan dan melupus harta awam(kecuali tanah) dalam Persekutuan dan Negeri. Oleh yang demikian AP adalah dikuatkuasakan penggunaannya ke atas semua Kementerian dan Jabatan Persekutuan, Jabatan Kerajaan Negeri dan juga di terima pakai oleh sebahagian Badan-badan Berkanun. 9.2.3 Apakah pengubahsuaian / pengemaskinian yang telah dilakukan ? Arahan Perbendaharaan (semakan 1997) telah mengubahsuai/mengemaskini Arahan Perbendaharaan asal mengikut dasar-dasar, pekeliling-pekeliling dan peraturan-peraturan yang sedang berkuatkuasa pada masa itu. Tidak ada apa-apa perubahan/pengubahsuaian nyata (substantial) yang telah diperkenalkan dalam jilid ini. Aspek-aspek seperti berikut telah menjadi asas bagi pengemaskinian/pengubahsuaian yang telah dibuat:

i. segala pembaharuan yang telah diperkenalkan dalam pengurusan Kewangan di kalangan Kementerian/Jabatan/ Agensi Kerajaan semenjak tahun 1970;

ii. perubahan yang diperkenalkan di bawah pelaksanaan Sistem Belanjawan Program dan Prestasi dalam tahun-tahun 1970'an dan 1980'an serta Sistem Belanjawan Yang Diubahsuai semenjak tahun 1990;

iii. perubahan dan pengubahsuaian yang diperkenalkan dalam sistem perakaunan kerajaan; iv. pengubahsuaian yang diperlukan selaras dengan penggunaan komputer dan peralatan automasi

pejabat yang lain; v. pengemaskinian beberapa Arahan Perbendaharaan yang lama yang telah dilakukan melalui

pengeluaran Pekeliling Perbendaharaan dan Surat Pekeliling Perbendaharaan dari semasa ke semasa semenjak tahun 1970;

vi. pengemaskinian penggunaan istilah-istilah baru, ejaan-ejaan baru dan tatabahasa seperti mana yang diperkenalkan oleh Dewan Bahasa dan Pustaka;

vii. penggunaan sistem metrik untuk menggantikan sistem ukuran sukatan tradisional; viii. penyesuaian dan perubahan yang diperkenalkan kepada tatacara pengurusan stor, pekeliling-

pekeliling dan peraturan-peraturan yang dikeluarkan dari semasa ke semasa; dan ix. beberapa arahan-arahan yang dianggap telah menjadi usang telahpun dikeluarkan daripada AP

asal.

Arahan Perbendaharaan (yang sedang dalam pindaan untuk kali kedua) pula telah mengambilkira beberapa aspek seperti berikut:

i. pindaan-pindaan yang dibuat melalui Surat Pekeliling Perbendaharaan dan Pekeliling Perbendaharaan semenjak 1997 hingga sekarang;

ii. pembaharuan-pembaharuan yang telah diperkenalkan dalam pengurusan kewangan dan perakaunan selain daripada Pekeliling Perbendaharaan dan Surat Pekeliling Perbendaharaan;

iii. pengubahsuaian dalam sistem perakaunan dan penggunaan sistem berkomputer dan peralatan automasi pejabat selaras dengan pelaksanaan Kerajaan Elektronik; dan

iv. mengemaskini istilah, ejaan dan tatabahasa yang baru seperti yang digunapakai oleh Dewan Bahasa dan Pustaka.


March 2009 9-3

9.2.4 Pengenalan kepada bab A : Tatacara kewangan Bab ini menjelaskan tatacara mengenai pemberian kuasa oleh badan perundangan bagi perbelanjaan operasi dan pembangunan serta bagaimana perbelanjaan-perbelanjaan itu, selepas diluluskan oleh badan perundangan, dilakukan dengan tertakluk selanjutnya kepada kawalan Perbendaharaan. Ia juga menjelaskan tatacara mengenai pindah peruntukan dan anggaran tambahan. Tujuannya ialah untuk menjelaskan dan bukan menggantikan pelbagai peruntukan perlembagaan dan undang-undang dan jika sekiranya didapati apa-apa pertentangan antara Arahan-arahan ini dengan peruntukan-peruntukan perlembagaan dan undang-undang itu, peruntukan perlembagaan dan undang-undang tersebut mestilah dipakai. 9.2.5 Pengenalan kepada bab B : Tatacara perakaunan Bab ini dibahagikan kepada tiga seksyen di bawah tajuk-tajuk berikut:

I - Mengawal Terimaan dan Bayaran dan Menyimpan Wang Awam;

II - Perakaunan; dan

III - Tatacara Perolehan Bekalan, Perkhidmatan dan Kerja.

Kawalan perbelanjaan sekarang terletak pada Pegawai-pegawai Pengawal yang pada amnya adalah Ketua-ketua Setiausaha Kementerian dan Ketua-ketua Jabatan. Konsep mengenai Pegawai Pengawal telah diperkenalkan dalam tahun 1961 dan Akta Tatacara Kewangan 1957 (Disemak - 1972) telah dipinda untuk mengambil kira konsep baru ini.

Di bawah Seksyen II diterangkan tanggungjawab Ketua Setiausaha Perbendaharaan, Akauntan Negara, Pegawai Kewangan Negeri dan Akauntan Negeri/Bendahari Negeri dalam perkara-perkara mengenai Tatacara perakaunan.

Tatacara mengenai barang-barang dan kerja-kerja di bawah Seksyen III telah berubah dari tatacara yang sedia ada. Ini berlandaskan kepada faktor dimana industri tempatan telah berkembang dengan pesatnya di negara ini. Perolehan barang-barang hendaklah diberi keutamaan kepada industri tempatan berbanding dengan bekalan luar negeri.

Pembelian pukal di bawah kontrak pusat diselenggarakan oleh Perbendaharaan atau Jabatan yang mempunyai stor simpanan besar. Ini adalah untuk mendapatkan faedah dari pembelian cara besar-besaran, kecekapan menyimpan barang-barang dan amalan kawalan barang-barang cara moden. Ini boleh menjimatkan perbelanjaan Kerajaan dan memberi perkhidmatan lebih baik dan cepat kepada Jabatan-jabatan. Sistem perolehan pusat ini boleh juga menolong Jabatan untuk memperbaiki cara mendapatkan bekalan sendiri dan cara kawalan inventori. 9.2.6 Pengenalan kepada bab C : Audit, kehilangan dan tatacara hapus kira Peruntukan-peruntukan dalam Bab ini menegaskan tanggungjawab Pegawai Pengawal mengenai perbelanjaan, pemungutan, dsb. yang sepatutnya berkenaan wang dan barang-barang awam di bawah jagaannya dan tatacara yang perlu diikuti sekiranya berlaku apa-apa kehilangan atau sekiranya tatacara-tatacara perakaunan tidak dipatuhi. Bab ini juga menjelaskan tatacara yang perlu diambil oleh Ketua Setiausaha Perbendaharaan atau Pegawai Kewangan Negeri apabila menerima Laporan Ketua Audit Negara mengenai Akaun Awam.


9-4 March 2009

Tanggungjawab Pegawai Pengawal untuk memberikan penjelasan kepada Jawatankuasa Akaun Awam mengenai apa-apa perenggan yang berkaitan dengan Kementeriannya juga dinyatakan di dalam Bab ini. Ketua Setiausaha Perbendaharaan atau Pegawai Kewangan Negeri juga perlu menghantar kepada Jawatankuasa Akaun Awam suatu memorandum muktamad mengenai perkara yang disebutkan dalam Laporan Jawankuasa Akaun Awam.

Kuasa Ketua Audit Negara yang diperuntukkan di bawah Seksyen 7, Akta Audit 1957 juga diperjelaskan di dalam bab ini. Antaranya ialah kuasa Ketua Audit Negara atau seseorang Pegawai yang diwakilkan olehnya dengan bertulis adalah berhak untuk melihat segala rekod, buku, baucar, dokumen, wang tunai, setem, cagaran, barang-barang atau harta benda lain yang tertakluk kepada auditannya. Semua pegawai awam juga perlu memberi segala kemudahan yang diperlukan oleh Ketua Audit Negara dan menjawab apa-apa pertanyaan audit tidak lewat dari satu bulan daripada tarikh pertanyaan audit tersebut. Adalah menjadi tanggungjawab Ketua Audit Negara untuk memeriksa dan melaporkan apa-apa perkara yang tidak memuaskan yang tidak memuaskan yang berkaitan dengan akaun atau kewangan awam. Seseorang pegawai awam tidak pula terlepas dari tanggungjawabnya supaya mematuhi atau mendapatkan pematuhan arahan-arahan dalam bidang kuasanya sendiri.

Akta Tatacara Kewangan 1957 (Disemak - 1972) memperuntukkan kuasa undang-undang untuk menghapuskira kehilangan dan di mana perlu untuk tindakan surcaj diambil terhadap pegawai-pegawai yang bertanggungjawab atas sesuatu kehilangan. Bab ini menyenaraikan dengan lengkap tatacara yang perlu dipatuhi. 9.3 PROCEDURE FOR GOVERNMENTS DEPARTMENT 9.3.1 Peranan dan tanggungjawab pegawai pengawal Bagi memastikan pengurusan Aset Alih Kerajaan dilaksanakan secara teratur, cekap dan berkesan di Kementerian/Jabatan, peranan dan tanggungjawab Pegawai Pengawal dalam pengurusan Aset Alih Kerajaan diberi penekanan. a) Mewujudkan Unit Pengurusan Aset. b) Melantik: i) Pegawai Aset di peringkat Kementerian/Jabatan /Pusat Tanggungjawab (PTJ); ii) Pegawai-pegawai menjalankan pemeriksaan ke atas aset; iii) Lembaga Pemeriksa bagi melaksanakan pelupusan aset; dan iv) Jawatankuasa Penyiasat bagi kes kehilangan aset.

c) Menubuhkan Jawatankuasa Pengurusan Aset Kerajaan (JKPAK)

d) Mengemukakan laporan tahunan ke Perbendaharaan sebelum 15 Mac tahun berikutnya: i) Laporan Harta Modal dan Inventori (Kew. PA-8); ii) Sijil Tahunan Pemeriksaan Harta Modal dan Inventori Kew. PA-12; iii) Laporan Tahunan Pelupusan Aset Alih Kerajaan; (Kew. PA-20); dan iv) Laporan Tindakan Surcaj dan Tatatertib (Kew. PA-32).

e) Memastikan aset alih Kerajaan diuruskan mengikut tatacara yang telah ditetapkan


March 2009 9-5

9.3.2 Tugas dan tanggungjawab unit pengurusan aset a) Menguruskan semua aset alih Kerajaan di Kementerian/Jabatan meliputi: i) Penerimaan ii) Pendaftaran iii) Penggunaan, penyimpanan dan pemeriksaan iv) Penyelenggaraan v) Pelupusan vi) Kehilangan dan Hapus kira

b) Menguruskan perlantikan Pegawai Pemeriksa, Lembaga Pemeriksa dan Jawatankuasa Penyiasat. c) Menjadi Urus Setia kepada JKPAK. d) Mengurus pelupusan aset alih Kerajaan. e) Mengurus Kehilangan dan Hapus kira. f) Menyelaras penyediaan laporan berikut: • Harta Modal dan Inventori • Sijil Tahunan Pemeriksaan Harta Modal dan Inventori • Pelupusan Aset Alih Kerajaan • Tindakan Surcaj/Tatatertib 9.3.3 Penguatkuasaan Peraturan hendaklah dilaksanakan oleh Kementerian/ Jabatan berkuatkuasa mulai 02 Mac 2007. Semua Pegawai Pengawal hendaklah memastikan setiap Kementerian/Jabatan di bawah kawalannya menguruskan aset alih mengikut TPA melainkan jika terdapat arahan lain yang dikeluarkan oleh Perbendaharaan. 9.3.4 Pelaksanaan Semua aset yang dimiliki oleh Kementerian/Jabatan sebelum tahun 2007, hendaklah disenaraikan dalam Senarai Daftar Harta Modal Kew. PA-4 dan Senarai Daftar Inventori Kew. PA-5. Maklumat dalam Daftar Stok Bekalan Pejabat (Kew.314) hendaklah dipindahkan ke Kad Kawalan Stok (Kew. 300-J3) dan Kad Petak (Kew. 300-J4) mengikut Panduan Perbendaharaan Tatacara Pengurusan Stor (PP-TPS). 9.3.5 Pembatalan Peraturan berkaitan pengurusan aset yang terkandung dalam AP, PP-TPS, PP dan SPP berikut dibatalkan: a) AP Bab II – Kehilangan dan Hapus kira, hanya peraturan berkaitan barang-barang awam sahaja; b) PP Bil. 3 Tahun 1990, hanya berkaitan barang-barang awam sahaja; c) PP Bil 2 Tahun 1991; d) SPP Bil. 7 Tahun 1995; e) SPP Bil. 2 Tahun 1997; f) SPP Bil. 3 Tahun 2002; g) PP Bil. 8 Tahun 2004 hanya para 8 Pengurusan Stor dan aset sahaja; h) Panduan Perbendaharaan Tatacara Pengurusan Stor hanya Bab XIV dan XV sahaja; i) Surat Perbendaharaan S(K&B)(8.09)735/3/1-335(SJ.1) JD.4 bertarikh 19 Jun 1995; dan j) Surat Perbendaharaan K.KEW/BKP/PA/535/457 bertarikh 7 Januari 2002.


9-6 March 2009

9.3.6 Pemakaian Tertakluk kepada penerimaannya oleh pihak berkuasa masing-masing, Pekeliling ini dipanjangkan kepada semua Perkhidmatan Negeri, Badan Berkanun dan Pihak Berkuasa Tempatan. 9.4 TATACARA PENGURUSAN ASET(TPA)

PENDAHULUAN

TPA

BAB A PENERIMAAN

BAB E PELUPUSAN

BAB B PENDAFTARAN

BAB C PENGGUNAAN, PENYIMPANAN &

PEMERIKSAAN

BAB F KEHILANGAN /HAPUS KIRA

BAB D PENYELENGGARAAN

Fig. 9.1 Carta Aliran untuk Tatacara Pengurusan Aset(TPA) 9.4.1 Pendahuluan TPA ialah tatacara bagi menguruskan Harta Modal dan Inventori meliputi: Bab A : Penerimaan Bab B : Pendaftaran Bab C : Penggunaan, Penyimpanan dan Pemeriksaan Bab D : Penyelenggaraan Bab E : Pelupusan Bab F : Kehilangan dan Hapus kira 9.4.1.1 Definisi aset Aset bermaksud harta benda kepunyaan atau milikan atau di bawah kawalan Kerajaan yang dibeli atau yang disewa beli dengan wang Kerajaan, yang diterima melalui sumbangan atau hadiah atau diperolehi melalui proses perundangan. 9.4.1.2 Definisi aset alih Aset Alih bermaksud aset yang boleh dipindahkan dari satu tempat ke satu tempat yang lain termasuk aset yang dibekalkan atau dipasang bersekali dengan bangunan.


March 2009 9-7

9.4.1.3 Harta modal Aset Alih yang harga perolehan asalnya RM1,000 dan ke atas setiap satu pada masa perolehan. Aset alih yang memerlukan penyelenggaraan secara berjadual tanpa mengira harga perolehan asal. Penyelenggaraan secara berjadual merujuk kepada aset yang memerlukan penyelenggaraan seperti yang telah dinyatakan dalam manual/buku panduan pengguna. 9.4.1.4 Inventori Aset Alih yang harga perolehan asalnya kurang daripada RM1,000 setiap satu dan tidak memerlukan penyelenggaraan berjadual. Perabot, hamparan, hiasan, langsir dan pinggan mangkuk tanpa mengira harga perolehan asal.

9.4.1.5 Kategori harta modal Tiga (3) kategori Harta Modal iaitu: a) Loji/Jentera Berat b) Kenderaan c) Peralatan / Kelengkapan ICT / Telekomunikasi / Penyiaran / Perubatan / Pejabat / Makmal /

Bengkel / Dapur / Sukan

9.4.1.6 Kategori inventori Empat (4) kategori Inventori iaitu: a) Nilai perolehan asal kurang daripada RM1,000 dan tidak memerlukan penyelenggaraan secara

berjadual:

i) Peralatan / Kelengkapan ICT / Telekomunikasi / Penyiaran / Perubatan / Pejabat / Makmal / Bengkel / Dapur / Sukan

b) Tanpa mengira nilai perolehan asal:

i) Perabot ii) Hamparan, hiasan dan langsir iii) Pinggan mangkuk

9.4.2 Bab A – Penerimaan “Pegawai Penerima” ialah pegawai yang diberi tanggungjawab untuk menerima dan mengesahkan aset yang diperolehi. “Pegawai Bertauliah” ialah pegawai yang memiliki kepakaran dalam bidang tertentu. Objektif Penerimaan: a) Memastikan setiap aset diterima menepati spesifikasi yang ditetapkan. b) Menentukan kualiti dan kuantiti sebenar mengikut pesanan. c) Memastikan aset diterima dalam keadaan yang baik, sempurna dan selamat untuk digunakan.


9-8 March 2009

Peraturan penerima: a) Pemeriksaan teliti bagi memastikan aset diterima menepati spesifikasi. b) Pemeriksaan teknikal pegawai yang bertauliah bila perlu. c) Langkah-langkah yang perlu dipatuhi semasa menerima aset:

i) Semak butiran dalam dokumen. ii) Periksa, kira, ukur, timbang atau uji serta merta sebelum sahkan penerimaan. Sekiranya

pengesahan tidak dapat dilakukan serta merta maka dokumen dicatat “ Diterima dengan syarat ianya diperiksa, dikira,diukur, ditimbang dan diuji”.

d) Sediakan Borang Laporan Penerimaan Kew. PA-1(Rujuk kepada Fig. 9.1) jika terdapat

kerosakan/perselisihan. e) Borang Kew.PA-1 yang ditandatangani oleh Ketua Jabatan dihantar kepada agen penghantaran

atau syarikat pembekal. f) Pegawai Penerima pastikan aset diterima beserta Surat Jaminan daripada pembekal. g) Pegawai Penerima pastikan aset diterima bersama manual penggunaan dan penyelenggaraan.


March 2009 9-9

Fig. 9.2 KEW.PA-1 - Borang Laporan Penerimaan Aset


9-10 March 2009

9.4.3 Bab B 9.4.3.1 Pendaftaran

PENDAFTARAN

TEMPOH MENDAFTAR

PUNCA MAKLUMAT

OBJEKTIF

PENDAFTARAN ASET HADIAH

LAPORAN TAHUNAN HARTA MODAL &

INVENTORI

CARTA ALIRAN DAN PROSES KERJA

DOKUMEN PENDAFTARAN

PENDAFTARAN ASET LUCUTHAK

BUTIRAN MAKLUMAT

PENGESAHAN PENDAFTARAN

URUSAN PENDAFTARAN ASET ALIH

Fig. 9.3 – Carta Aliran untuk Pendaftaran Aset

9.4.3.2 Objectif pendaftaran • Mewujudkan pangkalan data yang lengkap, tepat dan kemaskini • Memudahkan pengesanan dan pemantauan • Membolehkan keadaan aset diketahui • Memudahkan penyelenggaraan, pelupusan dan penggantian aset 9.4.3.3 Tempoh mendaftar Dua (2) minggu dari tarikh pengesahan penerimaan 9.4.3.4 Pendaftaran aset hadiah Aset yang diterima secara hadiah bagi tujuan pembelajaran dan pameran tidak perlu didaftarkan. Satu senarai daftar aset berkenaan diwujudkan bagi tujuan rekod.

9.4.3.5 Pendaftaran aset lucuthak Didaftarkan jika Kementerian/Jabatan bercadang menggunakannya. Aset lucuthak yang dikategorikan di bawah akta tertentu menjadi tanggungjawab Pegawai Pengawal untuk menentukan tindakan yang diambil ke atas aset berkenaan mengikut maksud tersebut sahaja.


March 2009 9-11

9.4.3.6 Punca maklumat Aset Yang Dibeli: a) Pesanan Rasmi Kerajaan b) Nota Serahan c) Invois d) Dokumen Kontrak e) Kad Jaminan f) Manual Pengguna g) Dokumen-dokumen lain yang berkaitan Aset yang disewa beli: a) Surat Ikatan Perjanjian b) Dokumen lain yang berkaitan Aset Yang Diterima Daripada Sumber Lain a) Salinan Daftar jika diterima secara pindahan b) Salinan surat kelulusan menerima hadiah (Pek. Perkhidmatan Bil. 3 Tahun 1998). c) Salinan Sijil Lucuthak oleh Mahkamah Aset Yang Belum Berdaftar: Sekiranya tiada punca maklumat, pendaftaran berasaskan maklumat di fizikal aset atau sumber-sumber lain yang berkaitan. 9.4.3.7 Dokumen pendaftaran a) Daftar Harta Modal Kew. PA-2 (Rujuk kepada Fig. 9.2) b) Daftar Inventori Kew. PA-3(Rujuk kepada Fig. 9.3) Pendaftaran melalui sistem berkomputer: a) Format yang sama diguna pakai. b) Daftar hendaklah dicetak. c) Ditandatangani oleh Ketua Jabatan.


9-12 March 2009

KEW. PA-2

(No. Siri Pendafataran: KK/BKP10/H/07/1

DAFTAR HARTA MODAL Kementerian/Jabatan: Pebendaharaan Bahagian:Kawalan dan Pemantauan

BAHAGIAN A

Malaysia Buatan

Tandatangan Ketua Jabatan: Ń

Nama: Noorrizan bt. Shafie Jawatan Setiausaha Bahagian

Compter System Sdn. Bhd No. 15, Plaza Low Yatt, Jalan

Embi

Nama Pembekal Dan Alamat 1 Tahun Tempoh Jaminan KOMPONEN/AKSESORI

CPU Papan Kekunci Monitor Tetikus Speaker

LO A5624 No. Pesanan Rasmi Kerajaan No. Pendaftaran 13 April 2007 Tarikh Diterima DP/NO7N22 No. Casis/Siri Pembuat RM8,500 Harga Perolehan Asal Jenis dan No. Enjin

DELL/L1506 Jenis/Jenama/Model Komputer Sub Kategori Peralatan ICT Kategori Kod Nasional

ƒ Tandatangan

Ahmad Hishamuddin Nama Pegawai

17 April 2007 Tarikh

PKP(P) Lokasi PENEMPATAN

Tandatangan

Nama Pemeriksa

Status Aset

Tarikh

PEMERIKSAAN

Tandatangan Kaedah Pelupusan Tarikh Rujukan Kelulusan

PELUPUSAN/HAPUS KIRA

KEW. PA-2 DAFTAR HARTA MODAL

BUTIR-BUTIR PENAMBAHAN, PENGGANTIAN DAN NAIKTARAF

BAHAGIAN B

1,0001 tahunPenggantian CPU21.6.2007 1.

Nama dan Tandatangan

Kos (RM)Tempoh jaminanButiran Tarikh Bil.

Fig. 9.4 - KEW.PA-2 - Daftar Harta Modal


March 2009 9-13

KEW. PA-3

(No. Siri Pendafataran KK/BKP10/I/07/1-5

Bahagian: Kawalan dan Pemantauan

Tandatangan Ketua Jabatan: Ń

Nama: Nooorizan bt. Shafie

Jawatan; Setiausaha Bahagian

Nama Pembekal dan Alamat

Syarikat Sri Kenanga Sdn. Bhd.

Lot 50 Jalan Tuanku Abdul Rahman

LO CT3456 No. Pesanan Rasmi Kerajaan 1 Tahun Tempoh Jaminan

17 Mei 2007 Tarikh Diterimabuah Unit Pengukuran

RM350.00 sebuah Harga Perolehan Asal5 Kuantiti

Almari Buku BercerminJenis

Almari Sub Kategori

Perabot Kategori

Kod Nasional

HAHŤ Ñ Tandatangan

Henry Chong Ahmad Nik HassanTajol AzharNoorrizan bt. Nama Pegawai

22 Mei 2007 22 Mei 200722 Mei 200722 Mei 200722 Mei 2007 Tarikh

PPT(P) Pkp(p)TSBKP(S)TSBKP(A&p)SBKP Lokasi

KK/BKP10/1//KK/BKP10/1//KK/BKP10/1//KK/BKP10/1//KK/BKP10/1//No. Siri

1 111 1Kuantiti

PENEMPATAN

& ¥ & ¥& ¥& ¥ & ¥ Tandatangan

m & Hishaam & Hisham & Hishm & HishaHisham & Nama

Rosak Seang Seang Seang Seang Status Aset

22.6.2007 22.6.200722.6.200722.6.2007 22.6.2007 Tarikh PEMERIKSAAN

§ PPT(P)1BuangKK/BDSWP 10/767/2(81) 3.7.2007

Tandatangan LokasiKuantitiKaedah PelupusanRujukan Tarikh

PELUPUSAN/HAPUS KIRA

DAFTAR INVENTORIKementerian/Jabatan: Perbendahraan

Fig. 9.5 - KEW.PA-3 - Daftar Inventori


9-14 March 2009

9.4.3.8 Carta aliran dan proses kerja pendaftaran

Carta Aliran dan Proses Kerja Pendaftaran seperti Jadual 1 dan Jadual 2.

Table 9.1 Carta Aliran Pendaftaran Aset Alih Kerajaan Di Peringkat Kementerian/Jabatan/PT


March 2009 9-15

Table 9.2 Proses Kerja Pendaftaran Aset Alih Kerajaan


9-16 March 2009

9.4.4 Bab C – Penggunaan, penyimpanan dan pemeriksaan 9.4.4.1 Objektif penggunaan, penyimpanan dan pemeriksaan Aset Kerajaan hendaklah dikendali dengan cekap, mahir dan teratur bagi tujuan: a) Mengurangkan pembaziran b) Menjimatkan kos c) Mencapai jangkahayat d) Mencegah penyalahgunaan e) Mengelakkan kehilangan 9.4.4.2 Penggunaan a) Bagi tujuan rasmi sahaja. b) Mengikut fungsi sebenar dalam manual. c) Dikendali oleh pegawai yang mahir dan berkelayakan. d) Perlu direkodkan. e) Melapor kerosakan dalam Borang Aduan Kerosakan Kew. PA-9. Aset yang dibawa keluar dari pejabat hendaklah mendapat kebenaran bertulis daripada Ketua Jabatan. Aset dipulangkan semula sebaik selesai penggunaannya atau mengikut tempoh kelulusan mana lebih awal. Peraturan mengenai Penggunaan, Pengurusan dan Penyelenggaraan kenderaan adalah mengikut peraturan semasa yang berkuatkuasa.(PP Bil.2 Tahun 1980 dan PP Bil 7 Tahun 1985) 9.4.4.3 Penyimpanan • Aset hendaklah sentiasa disimpan di tempat yang selamat dan sentiasa di bawah kawalan

pegawai bertanggungjawab. Arahan Keselamatan Kerajaan hendaklah sentiasa dipatuhi. • Setiap pegawai adalah bertanggungjawab terhadap apa-apa kekurangan, kerosakan atau

kehilangan aset di bawah tanggungjawabnya. • Aset yang sangat menarik atau bernilai tinggi hendaklah sentiasa di bawah kawalan maksima. • Pegawai yang gagal mematuhi peraturan boleh dikenakan tindakan termasuk surcaj di bawah

Seksyen 18(c) Akta Prosedur Kewangan 1957. 9.4.4.4 Pemeriksaan Pemeriksaan aset dilaksanakan ke atas: a) Fizikal b) Rekod c) Penempatan Tujuan pemeriksaan adalah untuk: a) Mengetahui keadaan dan prestasi aset; b) Memastikan setiap aset yang mempunyai daftar/rekod yang lengkap, tepat dan kemaskini; c) Memastikan setiap aset berada di lokasi sama seperti yang tercatat dalam daftar. • Pegawai Pengawal melantik sekurang-kurangnya 2 orang Pegawai Pemeriksa. • Pemeriksaan hendaklah dilaksanakan sekurang- kurangnya sekali setahun.


March 2009 9-17

• Pegawai Pemeriksa mengemukakan Laporan Pemeriksaan Harta Modal Kew. PA-10 dan

Laporan Pemeriksaan Inventori Kew. PA-11 kepada Ketua Jabatan. • Ketua Jabatan kemuka Kew. PA-10 dan Kew. PA-11 bersama-sama Sijil Tahunan Pemeriksaan

Harta Modalm dan Inventori Kew. PA-12 kepada Pegawai Pengawal. • Pegawai Pengawal dikehendaki mengemukakan Kew. PA-12 kepada Perbendaharaan sebelum 15

Mac tahun berikutnya. • Ketua Jabatan hendaklah melakukan sendiri pemeriksaan dari masa ke semasa bagi

memastikan peraturan ini dipatuhi. 9.4.5 Bab E – Pelupusan 9.4.5.1 Definisi pelupusan Pelupusan ialah satu proses untuk mengeluarkan aset dari milikan, kawalan,simpanan dan rekod mengikut kaedah yang ditetapkan. 9.4.5.2 Objektif pelupusan • Memastikan Jabatan Kerajaan tidak menyimpan aset yang tidak digunakan atau diperlukan. • Menjimatkan ruang simpanan/pejabat. • Mendapatkan hasil pulangan yang terbaik. • Membolehkan aset milik Kementerian / Jabatan dipindahkan ke Kementerian/ Jabatan lain. 9.4.5.3 Justifikasi pelupusan • Tidak Ekonomik Dibaiki • Pembekal tidak lagi memberi khidmat sokongan • Usang/Obselete • Disyor selepas pemeriksaan aset • Rosak & tidak boleh digunakan • Tidak lagi diperlukan oleh Jabatan • Luput tempoh penggunaan • Perubahan Teknologi • Keupayaan aset tidak lagi di peringkat optimum • Melebihi keperluan • Tiada alat ganti 9.4.5.4 Kuasa melulus pelupusan Dua (2) peringkat: a) Perbendaharaan b) Kementerian/Jabatan 9.4.5.5 Kuasa melulus perbendaharaan a) Nilai perolehan asal satu aset melebihi RM50,000 atau jumlah keseluruhan melebihi RM500,000;

dan

b) Semua kaedah pelupusan tanpa mengira nilai seperti berikut: i) Hadiah ii) Pindahan dari Jabatan Persekutuan ke Negeri iii) Tukar Beli (trade in)


9-18 March 2009

iv) Tukar Barang (barter trade) v) Kaedah lain pelupusan yang tidak dinyatakan dalam tatacara ini. 9.4.5.6 Kuasa melulus kementerian/jabatan a) Nilai perolehan asal satu aset tidak melebihi RM50,000 atau jumlah keseluruhannya tidak

melebihi RM500,000; dan b) Pindahan aset di antara Jabatan Persekutuan bagi nilai perolehan asal tidak melebihi RM50,000

setiap satu atau jumlah keseluruhannya tidak melebihi RM500,000 . Pegawai-pegawai yang diwakilkan kuasa di bawah Seksyen 17 Akta Acara Kewangan 1957 tidak boleh mewakilkan kuasa selanjutnya kepada mana-mana pegawai lain. 9.4.5.7 Unit pengurusan aset kementerian/jabatan • Mengurus pelantikan Ahli Lembaga Pemeriksa mengikut Kew. PA-15 • Mendapatkan Perakuan Pelupusan (PEP) Kew. PA-16 • Mendapatkan Laporan Lembaga Pemeriksa Kew. PA-17 • Menyemak dan memastikan permohonan pelupusan lengkap dan teratur • Mengemukakan permohonan pelupusan kepada Kuasa Melulus 9.4.5.8 Pelantikan lembaga pemeriksa a) Pegawai Pengawal Kementerian/Jabatan perlu melantik Lembaga Pemeriksa bagi membuat

pemeriksaan. b) Lembaga Pemeriksa dilantik berdasarkan jawatan tidak lebih tempoh 2 tahun. 9.4.5.9 Keanggotaan lembaga pemeriksa a) Sekurang-kurangnya 2 orang pegawai (1 Pengerusi dan 1 Ahli) yang tidak terlibat secara

langsung dalam pengurusan aset berkenaan. b) Mempunyai kepakaran memeriksa aset jika perlu. c) Pegawai Kumpulan P&P atau Sokongan 1 atau yang setaraf. d) Pegawai dari Kementerian/Jabatan lain boleh dilantik jika perlu. 9.4.5.10 Tugas lembaga pemeriksa a) Menyedia dan mengemuka Jadual Pemeriksaan kepada Urus Setia Pelupusan Jabatan. b) Memeriksa aset dan rekod dalam tempoh 1 bulan. c) Memastikan maklumat sulit dan rahsia dalam peralatan yang hendak dilupuskan dikeluarkan. d) Menyedia Laporan Lembaga Pemeriksa Kew. PA-17. e) Mengesyor kaedah pelupusan yang sesuai. f) Menandatangani Kew. PA-17 dan kemuka ke Urus Setia. 9.4.5.11 Urus setia pelupusan a) Memaklumkan kelulusan kepada Ketua Jabatan untuk tindakan. b) Memohon pelanjutan tempoh pelupusan c) Memohon kelulusan meminda kaedah pelupusan d) Melantik 2 orang saksi bagi pelupusan kaedah pemusnahan e) Mendapatkan Sijil Penyaksian Pemusnahan Aset Kew. PA-18


March 2009 9-19

f) Memperolehi Sijil Pelupusan Aset Kew. PA-19 g) Menghantar Kew. PA-19 kepada Kuasa Melulus h) Mengemukakan Laporan Tahunan Pelupusan Aset Kew. PA-20 ke Perbendaharaan sebelum 15

Mac tahun berikutnya. 9.4.5.12 Kaedah pelupusan a) Jualan secara : Tender, Sebut harga, Lelong b) Jualan Sisa c) Tukar Barang (Barter Trade) d) Tukar Beli (Trade in) e) Tukar Ganti (Cannibalize) f) Pindahan g) Hadiah h) Musnah secara: Ditanam, Dibakar, Dibuang, Ditenggelam i) Kaedah lain pelupusan yang difikirkan sesuai

9.4.5.13 Tender • Gunakan Kew. PA-21 • Disertai oleh syarikat/orang perseorangan (Kew.PA-22) • Maklumat seperti dalam Kew. PA-21 diiklankan melalui sekurang-kurangnya 1 akhbar utama • Harga simpanan berdasarkan nilai semasa di Kew-PA-17 • Deposit tender 10% daripada harga tawaran tertakluk maksima RM10,000 • Tawaran dibuat guna sampul berlakri dan masukkan dalam peti tender Jabatan pada atau

sebelum tarikh dan waktu tutup yang ditetapkan. • Jawatankuasa Pembuka Tender dilantik oleh Pegawai Pengawal untuk membuka dan menjadual

tender. • Tender dibuka pada tarikh dan waktu yang ditetapkan. • Tawaran disenaraikan dalam Kew. PA-23 • Jadual Tender dan dokumen dikemuka kepada Ketua Jabatan. • Ketua Jabatan membuat penilaian dan perakuan tender. • Perakuan hendaklah disertakan bersama dengan salinan iklan tender, jadual pembukaan tender

dan dokumen lain. • Tawaran tertinggi yang dipilih tidak kurang 70% harga simpanan. Jika kurang rujuk

Perbendahraan. • Dalam memproses tender, Pegawai Pengawal hendaklah memastikan bahawa beliau dan

pegawai-pegawai tidak mempunyai apa-apa kepentingan persendirian atau terletakhak. • Pegawai dari Kementerian/Jabatan yang melupuskan aset tidak dibenarkan menyertai tender. • Sekiranya petender yang berjaya menolak tawaran maka deposit tender tidak akan

dikembalikan. • Lembaga Perolehan dimaklumkan mengenai penolakan untuk membolehkannya menimbang

tawaran lain. • Jika tawaran lain terlalu rendah, tender boleh dipelawa semula atau rujuk ke Perbendaharan

bagi mendapatkan kelulusan. • Jika tiada sebarang tawaran diterima, tender boleh dipelawa semula atau mohon pinda kaedah

pelupusan dari Kuasa Melulus.


9-20 March 2009

9.4.5.14 Sebut harga • Dipelawa 10 syarikat atau orang perseorangan • Kenyataan Tawaran Sebutharga dalam Kew. PA-24 • Tawaran sebut harga menggunakan Kew. PA-25 • Harga simpanan berdasarkan nilai semasa di Kew-PA-17 • Deposit tender 10% daripada harga tawaran tertakluk maksima RM5,000 • Tawaran dikemuka dalam sampul berlakri dan masukkan dalam peti sebut harga Jabatan pada

atau sebelum tarikh danwaktu tutup yang ditetapkan. • Sebut harga dibuka pada tarikh dan waktu yang ditetapkan. • Jawatankuasa Sebut Harga dilantik secara bertulis oleh Pegawai Pengawal. • Jawatankuasa Sebutharga menyenaraikan tawaran dalam menggunakan Borang Kew. PA-26 • Jawatankuasa Pembuka Sebut Harga mengemukakan Jadual Sebut harga kepada Urusetia untuk

menilai dan membuat perakuan kepada Jawatankuasa Sebutharga Jabatan untuk pertimbangan dan keputusan.

• Dalam memproses sebut harga Ketua Jabatan hendaklah memastikan beliau dan pegawai-pegawai tidak mempunyai sebarang kepentingan persendirian atau terletakhak.

• Penyebutharga yang berjaya diberitahu dengan serta merta. Sekiranya penyebutharga terpilih menolak tawaran, deposit sebut harga tidak akan dikembalikan. Jawatankuasa Sebut harga menimbang tawaran lain atau memutuskan pelawaan sebut harga semula.

• Pegawai Kementerian/jabatan yang melupuskan aset tidak dibenar menyertai sebut harga.

9.4.5.15 Lelong Dilaksanakan ke atas aset berikut: • Mempunyai nilai pasaran • Kuantiti yang banyak • Terdapat permintaan yang tinggi untuk membelinya. • Kenyataan Lelong mengandungi maklumat mengenai tarikh, waktu dan tempat. Contoh

kenyataan lelong di Kew. PA-27. • Harga simpanan berdasarkan nilai semasa di Kew. PA-17 dinyatakan dalam senarai aset yang

akan dilelong. • Urusan lelong di adakan diruang terbuka atau di dewan. • Pembida yang berminat untuk sertai lelongan, perlu mendaftar. Bayaran deposit RM1,000 atau

maksima RM1,000 • Pembida yang berjaya jelaskan bayaran dalam tempoh 7 hari dan aset diambil dalam tempoh 14

hari dari tarikh lelongan. • Sekiranya harga tawaran tertinggi kurang 70% daripada harga simpanan rujuk kepada

Perbendaharaan. 9.4.5.16 Jualan sisa • Dilaksanakan bagi aset yang tidak boleh digunakan dalam bentuk dan fungsi asalnya yang

mempunyai kandungan logam (besi, tembaga dll), getah, kayu, plastik dan sebagainya yang mempunyai nilai jualan.

• Jualan Sisa dilaksanakan dengan cara: - Tender - Sebut harga - Syarikat Bumiputera berdaftar dengan Kementerian Kewangan dalam bidang Membeli Barang

Lusuh (perlu permit)


March 2009 9-21

9.4.5.17 Tukar barang (Barter trade) • Aset dari jenis yang sama atau berbeza melalui tender terhad • Mempunyai justifikasi dan memperolehi kelulusan Perbendaharaan tanpa mengira nilai perolehan

asal • Kaedah tukar barang dilaksanakan berasaskan:

- Nilai aset hendaklah dianggarkan oleh pihak yang pakar dalam bidang berkenaan. - Aset yang mempunyai unsur keselamatan. - Pertukaran aset adalah berasaskan nilai terbaik. - Pertukaran aset berasaskan keperluan sebenar. - Syarikat dihadkan kepada 5-10 sahaja dan mempunyai lesen dan kemahiran. - Syarikat pengeluar atau agen pembekal aset baru hendaklah bertanggungjawab memberi

khidmat lepas jualan. 9.4.5.18 Tukar beli (Trade in) • Aset masih boleh diguna dalam bentuk asal tetapi tidak iperlukan oleh Kementerian/Jabatan dan

tiada Kementerian/ Jabatan yang berminat melainkan pembekal asal atau pembekal yang berniaga dalam bidang berkenaan.

• Mempunyai justifikasi dan memperolehi kelulusan Perbendaharaan tanpa mengira nilai • Dilaksanakan berasaskan: - Aset sama jenis - Aset perlu dikeluarkan sebelum pengganti dipasang - Penggantian aset disahkan oleh Jabatan Teknikal - Nilai semasa yang ditaksir oleh Jabatan Teknikal. - Peruntukan mencukupi bagi membiayai harga penuh aset yang akan diganti. - Harga jualan aset dikreditkan sebagai hasil Kerajaan dan tidak boleh ditolak dengan harga

sebenar aset yang dibeli. - Cadangan jualan tukar beli dimasukkan sebagai syarat dalam dokumen pelawaan

tender/sebutharga dan juga dalam perjanjian perolehan. 9.4.5.19 Tukar ganti (Cannibalize) • Dilaksanakan ke atas aset yang tidak ekonomi dibaiki tetapi boleh dikeluarkan bahagian-

bahagian tertentu seperti bahagian-bahagian jentera / kenderaan / perkakasan komputer dikeluarkan dan dipasang sebagai alat / komponen ganti bagi kenderaan / perkakasan komputer yang lain.

• Dilaksanakan berasaskan: - Aset yang sama jenis dan kegunaannya - Diperiksa dan disahkan kesesuaiannya oleh Pegawai Teknikal - Keperluan semasa bagi tujuan baik pulih dan penjimatan - Alat/komponen tukar ganti yang dipasang kepada aset penerima perlu direkodkan dalam

Bahagian B Kew. PA-2 berkenaan.


9-22 March 2009

9.4.5.20 Pindahan • Dilaksanakan antara Kementerian/Jabatan bagi aset yang boleh digunakan dalam bentuk asal

tetapi tidak diperlukan kerana: - Melebihi keperluan - Tidak diperlukan selepas projek siap - Obsolete/obsolescent • Kaedah pelupusan dilaksanakan berasaskan: - Permohonan atau kepeluan Kementerian/Jabatan - Tidak dikenakan apa-apa bayaran - Permohonan atau keperluan Kementerian/Jabatan. - Tidak dikenakan apa-apa bayaran. - Kos pengendalian pindahan ditanggung oleh penerima. - Daftar aset diserah kepada Kementerian/Jabatan penerima. - Aset yang diterima secara pindahan hendaklah dilupus oleh Kementerian / Jabatan - Surat Akuan Penerimaan hendaklah dikemukakan kepada Kuasa Melulus 9.4.5.21 Hadiah • Ciri-ciri aset yang boleh dilupuskan secara hadiah: - Aset boleh digunakan dalam bentuk dan fungsi asal tetapi tidak diperlukan oleh

Kementerian/Jabatan atau - Aset tidak ekonomi dibaiki tetapi boleh diguna sebagai bahan latihan atau pameran. • Pelupusan secara hadiah boleh dilaksanakan: - Antara Kementerian/Jabatan Kerajaan bagi tujuan latihan atau pemeran - Dari Kementerian/Jabatan Kerajaan kepada mana-mana organisasi, pertubuhan sukarela atau

badan-badan lain yang dianjurkan dan diiktiraf oleh Kerajaan. • Kaedah pelupusan secara hadiah dilaksanakan berasaskan: - Permohonan atau keperluan penerima - Kos pengendalian dan pengangkutan ditanggung oleh penerima. - Cadangan pelupusan secara hadiah disokong dengan surat permohonan Kementerian / Jabatan,

organisasi, pertubuhan sukarela atau badan badan lain. - Surat Akuan Penerimaan hendaklah dikemukakan kepada Perbendaharaan bersama Sijil

Pelupusan Kew. PA-19. - Aset yang diluluskan sebagai hadiah untuk tujuan latihan atau pameran diguna bagi tujuan

tersebut sahaja. 9.4.5.22 Musnah Kaedah pelupusan secara musnah dilaksanakan bagi aset yang tiada nilai jualan/nilai sisa atau aset yang berunsur keselamatan dengan cara berikut: - Ditanam - Dibakar - Dibuang - Ditenggelam


March 2009 9-23

Langkah-langkah yang perlu diambil: • Mendapat kelulusan PBT, JAS, Jabatan Laut dll. • Mematuhi garis panduan yang ditetapkan oleh Pihak Berkuasa berkenaan. • Bahan-bahan yang boleh diguna sebagai alat ganti hendaklah ditanggal / dikelurkan terlebih

dahulu • Tindakan bersesuaian seperti diketuk, dipotong, digelek dan sebagainya. • Sijil Penyaksian Pemusnahan Kew. PA-18 hendaklah disediakan.

9.4.5.23 Pelupusan melalui kontrak pusat Jika terdapat pelupusan melalui kontrak pusat Kementerian/Jabatan hendaklah menggunakan peraturan berkenaan. 9.4.5.24 Tindakan semasa melaksanakan pelupusan a) Label HKM dan nama Kem/Jab pada aset dipadamkan b) JPJ diberitahu diberitahu mengenai pelupusan kenderaan supaya pendaftaran kenderaan

dibatalkan c) Kad Pendaftaran kenderaan diserahkan kepada pembeli kecuali pelupusan secara jualan sisa d) Kenderaan Kerajaan dan aset alih lain yang telah dilupus dikecualikan daripada semua jenis

cukai


9-24 March 2009

9.4.5.24 Carta aliran dan proses kerja Carta Aliran dan Proses Kerja Pelupusan seperti di Jadual 3 dan Jadual 4.

Table 9.3 CARTA ALIRAN PELUPUSAN ASET ALIH


March 2009 9-25

Table 9.4 PROSES KERJA PELUPUSAN ASSET ALIH KERAJAAN

Langkah Proses Kerja

1 Kenal pasti aset yang perlu dilupuskan 2 Dapatkan PEP KEW.PA-16, jika perlu. 3 Sediakan maklumat aset dalam KEW.PA-17 seperti berikut:-

a) Keterangan aset b) Kuantiti c) Tarikh pembelian d) Tempoh digunakan/disimpan e) Nilai Perolehan Asal f) Nilai semasa

4 Pemeriksaan oleh Lembaga Pemeriksa 5 Lembaga Pemeriksa melengkapkan dan menandatangi KEW.PA-17 6 Kemukakan KEW.PA-17 kepada urus setia Pelupusan 7 Urus setia menyemak KEW.PA-17 dan pastikan dokumen sokongan berikut disertakan:-

a) PEP bagi asset mekanial/peralatan teknikal/perkakasan komputer b) Justifikasi Jabatan bagi syor kaedah tukar beli, tukar barang c) Laporan kemalangan bagi kenderaan terlibat dengan kemalangan d) Gambar aset, jika perlu e) Surat permohonan daripada Kementerian/ Jabatan/ Pertubuhan bagi kaedah

hadiah/ pindahan. 8 Jika laporan lengkap, terus ke proses 9 8a Jika laporan tidak lengkap, dikembalikan kepada Lembaga Pemeriksa 9 Urus setia menentukan kuasa Melulus 10 Urus setia menyemak bidang kuasa Melulus Kemukakan kepada Perbendaharaan jika:

i. Nilai perolehan asal melebihi RM 50,000 setiap satu atau jumlah keseluruhan

melebihi RM 500,000 ii. Syor kaedah pelupusan hadiah, pindah persekutuan ke negeri, tukar beli, tukar

barang atau kaedah lain yang tidak dinyatakan dalam TPA. 10(b) Kemukan kepada Kementerian/ Jabatan jika:

Nilai perolehan asal kurang daripada RM 50,000 setiap satu atau jumlah keseluruhan. Kurang daripada RM500,000

11 Jika pelupusan diluluskan, terus ke proses 12. 11(a) Jika pelupusan tidak diluluskan, laporan dikembalikkan kepada Urus setia Pelupusan

untuk mendapatkan maklumat lanjut. 12 Maklumkan keputusan kepada pemohon 13 Laksanakan pelupusan mengikut keputusan 14 Sediakan Sijil Pelupusan KEW.PA-19 15 Kemukankan Sijil Pelupusan Kepada Kuasa Melulus berserta:-

a) Salinan resit bagi pelupusan kaedah jualan b) Surat akuan terima bagi pelupusan kaedah pindahan/ hadiah c) Sijil Penyaksian Pemusnahan KEW.PA-18 bagi pelupusan kaedah musnah

16 Kemaskini rekod daftar aset.


9-26 March 2009

9.4.6 Bab F 9.4.6.1 Kehilangan dan hapus kira

HAPUS KIRA

OBJEKTIF

PROSES HAPUS KIRA

TAFSIRAN

KUASA MELULUS

URUS SETIA KEHILANGAN & HAPUS KIRA

CARTA ALIRAN DAN PROSES KERJA

(e) Tindakan Selepas

Kelulusan

(a)Melaporkan

Kehilangan

(b)Laporan Awal (c)Jawatankuasa

Penyiasat

(d) Laporan Akhir

Fig. 9.6 – Carta Aliran untuk Kehilangan dan Hapus Kira

9.4.6.2 Tafsiran kehilangan Kehilangan bermaksud aset yang tiada lagi dalam simpanan disebabkan oleh kecurian, kemalangan, kebakaran, bencana alam, kesusutan, penipuan atau kecuaian pegawai awam. 9.4.6.3 Tafsiran hapus kira Hapus kira ialah proses untuk membatalkan rekod aset yang hilang. 9.4.6.4 Kuasa melulus hapus kira Dua (2) peringkat: a) Perbendaharaan b) Pegawai Pengawal 9.4.6.5 Kuasa melulus peringkat perbendaharaan a) Nilai perolehan asal satu aset melebihi RM50,000 atau keseluruhannya melebihi RM500,000. b) Peralatan Elektronik, Komunikasi dan ICT seperti di bawah tanpa mengira nilai perolehan asal:

Telefon bimbit, walkie talkie, kamera digital, kamera video, komputer riba, palmtop/pocket PC, Personal Digital Assistant (PDA),LCD Projektor, Pemain CD/DVD dan smartphone.

c) Melibatkan kecurian, penipuan atau kecuaian pegawai awam tanpa mengira nilai perolehan asal.


March 2009 9-27

9.4.6.6 Kuasa melulus peringkat pegawai pengawal a) Nilai perolehan asal satu aset tidak melebihi RM50,000 atau jumlah keseluruhannya tidak

melebihi RM500,000 dan tidak melibatkan peralatan Elektronik, Komunikasi dan ICT; dan b) Pegawai Pengawal sebelum meluluskan apa-apa hapus kira hendaklah berpuashati bahawa soal

kecurian, penipuan atau kecuaian tidak melibatkan pegawai awam. 9.4.6.7 Urusetia kehilangan dan hapus kira Unit Pengurusan Aset di Kementerian/Jabatan bertanggungjawab sebagai Urus Setia Kehilangan dan Hapus kira. 9.4.6.8 Tugas a) Mendapatkan maklumat mengenai aset yang hilang Melalui Daftar Harta Modal (Kew. PA-2) dan

Daftar Inventori Kew. PA-3. b) Mendapatkan Laporan Awal Kew. PA-28 daripada Ketua Jabatan. c) Mengemuka Laporan Awal dan salinan Laporan Polis kepada Pegawai Pengawal. d) Menguruskan pelantikan Jawatankuasa Penyiasat dengan menggunakan contoh format Kew. PA-

29. e) Mendapatkan hasil siasatan polis. f) Mendapatkan Laporan Akhir Kew. PA-30 daripada Jawatankuasa Penyiasat. g) Mengemuka Laporan Akhir bagi mendapat ulasan dan syor daripada Pegawai Pengawal. h) Menyemak dan memastikan dokumen bagi permohonan hapus kira lengkap dan teratur. i) Mengemukakan permohonan hapus kira kepada Kuasa Melulus dalam tempoh 4 bulan dari tarikh

Laporan Awal dikemukakan walaupun hasil penyiasatan polis belum diperolehi. j) Memaklum keputusan kepada Ketua Jabatan untuk kemaskini rekod daftar aset. k) Memaklum syor surcaj atau tatatertib kepada Urus Setia Pihak Berkuasa Tatatertib untuk

tindakan selanjutnya l) Mendapatkan Sijil Hapus Kira Kew. PA-31 daripada Ketua Jabatan dan mengemukakan kepada

Kuasa Melulus dalam tempoh 1 bulan dari tarikh kelulusan hapus kira. m) Mendapatkan maklumbalas kedudukan tindakan surcaj/ tatatertib daripada Urus Setia Pihak

Berkuasa Tatatertib dan memaklumkan kepada Perbendaharaan. n) Menyedia dan mengemukakan Laporan Tahunan Tindakan Surcaj/Tatatertib Kew. PA-32 ke

Perbendaharaan tidak lewat dari 15 Mac tahun berikutnya. 9.4.6.9 Proses hapus kira a) Melaporkan Kehilangan i) Pegawai mengetahui kehilangan melaporkan kepada Ketua Jabatan dengan serta merta. ii) Ketua Jabatan atau pegawai yang bertanggungjawab ke atas kehilangan atau yang menjaga

aset atau yang mengetahui kehilangan berlaku hendaklah melaporkan kepada Polis dalam tempoh 24 jam dari waktu kehilangan diketahui.

b) Laporan Awal – Kew. PA-28 i) Ketua Jabatan hendaklah menyediakan Laporan Awal. Bagi kehilangan yang melibatkan seorang

Ketua Jabatan, Laporan Awal hendaklah disediakan oleh pegawai atasannya di peringkat Kementerian/ Ibu Pejabat.


9-28 March 2009

9.4.6.10 Carta aliran dan proses kerja Carta Aliran dan Proses Kerja Kehilangan dan Hapus kira seperti di Jadual 9.5 dan Jadual 9.6.

Table 9.5 CARTA ALIRAN HAPUS KIRA ASET


March 2009 9-29

Table 9.6 - PROSES KERJA HAPUS KIRA ASET ALIH KERAJAAN

Langkah Proses Kerja 1 Pegawai melaporkan kehilangan dengan serta merta kepada Ketua Jambatan. 2 Ketua Jambatan/pegawai yang berkenaan melaporkan segera kehilangan kepada Polis

dalam tempoh 24 jam dari waktu kehilangan diketahui. 3 Ketua Jambatan sediakan Laporan Awal KEW.PA-28 dalam tempoh 2 hari bekerja dari

tarikh kehilangan dan kemukakan kepada Pegawai Pengawal dan perbendaharaan beserta salinan Laporan Polis.

4 Pegawai Pengawal melantik Jawatankuasa Penyiasat dengan menggunakan format KEW.PA-29.

5 Jawatankuasa Penyiasat menjalankan siasatan. 6 Jawatankuasa Penyiasat menyediakan dan mengemukakan Laporan Akhir

KEW.PA-30 kepada Urus setia dalam tempoh (2)bulan dari tarikh perlantikan. 7 Urus setia menyemak Laporan Akhir. 8 Jika Laporan Akhir lengkap, terus ke proses 9. 8a Laporan yang tidak lengkap dikembalikan kepada Jawatankuasa Penyiasat. 9 Kemukakan Laporan Akhir yang lengkap kepada Pegawai Pengawal untuk mendapatkan

syor dan ulasan. 10 Pegawai Pengawal meneliti Laporan Akhir. 11 Setelah berpuas hati dengan hasil siasatan,terus ke proses 12. 11a Jika tidak berpuas hati,kembalikan kepada Urus setia untuk siasatan semula.

12

Pegawai Pengawal hendaklah:- a) Memberi syor dan ulasan;dan b) Meluluskan hapus kira jika:-

(i) Nilai perolehan asal kurang daripada RM50,000 setiap satu atau jumlah keseluruhan kurang daripada RM500,000 dan bukan aset yang dinyatakan di para 38.1(b); dan

(ii) Tidak melibatkan soal kecurian,penipuan atau kecuaian pegawai awam. 13 Kemukakan ke Perbendaharaan jika:-

a) Nilai perolehan asal melebihi RM50,000 setiap satu atau jumlah keseluruhan melebihi RM500,000;

b) Jenis aset seperti yang dinyatakan di para 38.1 (b) tanpa mengira nilai perolehan asalnya; dan

c) Melibatkan soal kecurian,penipuan atau kecuaian pegawai awam. 14 Perbendaharaan membuat pertimbangan dan keputusan. 15 Jika mendapat kelulusan daripada Perbendaharaan terus ke proses 16. 15a Jika Perbendaharaan memerlukan penjelasan lanjut, permohonan dikembalikan kepada

Pegawai Pengawal. 16 Perbendaharaan memaklumkan keputusan kepada Pegawai Pengawal. 17 Kementerian/Jabatan laksanakan keputusan dengan tindakan berikut:-

a) Catatkan kelulusan Hapus kira dalam Daftar Harta Modal/Inventor; b) Sediakan sijil Hapus kira Aset Alih Kerajaan KEW.PA-31; dan c) Syor surcaj/tatatertib jika ada, hendaklah dibawa ke Pihak Berkuasa Tatatertib

dalam tempoh tiga (3)bulan dari tarikh Surat Kelulusan Perbendaharaan. 18 Kementerian/Jabatan hendaklah:-

a) Mengemukakan Sijil Hapus Kira kepada Perbendaharaan dalam tempoh 1 bulan dari tarikh kelulusan; dan

b) Memaklumkan kedudukan tindakan surcaj/tatatertib (jika ada).


9-30 March 2009


CHAPTER 10 SCADA AND AUTOMATION SYSTEM

Chapter 10 SCADA AND AUTOMATION SYSTEM

March 2009 10-i

Table of Contents

Table of Contents .................................................................................................................. 10-i

List of Figures ...................................................................................................................... 10-ii

10.1 INTRODUCTION TO SCADA AND AUTOMATION SYSTEM .............................................. 10-1

10.1.1 Automation System ..................................................................................... 10-1

10.1.2 SCADA System ............................................................................................ 10-1

10.2 IMPLEMENTATION OF SCADA AND AUTOMATION SYSTEM IN BPME [BAHAGIAN PERKHIDMATAN MEKANIKAL & ELEKTRIKAL], DID ....................................................... 10-1

10.3 CONCEPT OF SCADA AND AUTOMATION SYSTEM ........................................................ 10-2

10.4 SCADA SYSTEM NETWORK TOPOLOGY ....................................................................... 10-5

10.4.1 Level 1 ....................................................................................................... 10-5

10.4.2 Level 2 ..................................................................................................... 10-12

10.4.3 Level 3 ..................................................................................................... 10-14

10.5 TIDAL CONTROL GATE (TCG) OR TIDAL CONTROL BARRAGE SCADA AND AUTOMATION SYSTEM .................................................................................................................. 10-15

10.5.1 Drainage and Irrigation Control Profile ........................................................ 10-15

10.5.2 Automatic Control mode ............................................................................ 10-16

10.5.3 Remote Control and Remote Monitoring Mode ............................................. 10-16

10.5.4 Manual Push Button Control Mode .............................................................. 10-16

10.5.5 Local Control Mode ................................................................................... 10-16

10.6 PUMP EXPERT SYSTEM ............................................................................................ 10-17

10.6.1 Pump Start Stop Sequence ........................................................................ 10-17

10.6.2 Pump Duty Time Accumulation and Maintenance ......................................... 10-18

10.6.3 Efficient Drainage and Irrigation Control ..................................................... 10-18

10.6.4 Pump Duty Performance and Total Volume Discharge .................................. 10-18

10.6.5 Electricity Energy Saving ............................................................................ 10-18

10.6.6 Components of Pump Expert System .......................................................... 10-19

10.7 INSTALLATION OF SCADA SYSTEM ........................................................................... 10-20

10.7.1 Installation of Automation System .............................................................. 10-20

10.7.2 Installation of SCADA System ..................................................................... 10-20

10.8 TESTING AND COMMISSIONING ............................................................................... 10-20

10.9 TRAINING REQUIREMENTS IN IMPLEMENTATION OF ICT AND ICA (INFORMATION & COMMUNICATION TECHNOLOGY/APPLICATION) SYSTEMS ......................................... 10-20

10.10 FACTORY INSPECTION AND TEST ............................................................................. 10-21

10.11 QUALITY ASSURANCE .............................................................................................. 10-21

10.12 MAINTENANCE OF SCADA SYSTEM ........................................................................... 10-22


10-ii March 2009

List of Figures

Figure

Description Page

10.1

10.2

SCADA And Automation System Configuration

Drainage And Irrigation SCADA System Network Topology

10-2

10-5


March 2009 10-1

10 SCADA AND AUTOMATION SYSTEM

10.1 INTRODUCTION TO SCADA AND AUTOMATION SYSTEM 10.1.1 Automation System A procedure or method used to regulate a system by combination of mechanical and electronic equipment that takes the place of human observation, effort, and decision. In content of gate automation, there is a combination of controller, sensors, contactor together with actuator to perform as Gate automation system. The equipment monitors water depths and gate positions so call water level sensor will get the analogue information of water depth and gate position from time to time. The sensed information is sent to controller to interpret by specially developed equations referred to as control algorithms. Development of control algorithm in gate automation control is very important which will determine the successfulness of the whole system. At the same time, collected data will be sent to server for SCADA analyzing and supervision purpose. 10.1.2 SCADA System SCADA stands for Supervisory Control and Data Acquisition. As the name indicates, it is not a full control system, but rather focuses on the supervisory level. As such, it is a purely software package that is positioned on top of hardware to which it is interfaced, in general via Remote Terminal Unit (RTU), or other commercial hardware modules or controllers. System operation and co-ordination include all normal operations, maintenance operations and efficient method for responding to system and/or device mis-operation, and an efficient critical event alert system for responding to emergency situations that arise.

SCADA system requires a communication system to maintain the data links between the master and site (Remote Terminal Unit (RTU)) where control and monitoring can be done through communication. The master station will perform the function of data collection from each sites and data storing logging, and manipulation tasks required by or for the operator. Each site requires remote site monitoring and control equipment, referred as Remote Terminal Unit (RTU), to monitor and control the remote site operations based on internal algorithms or commands received from master station. 10.2 IMPLEMENTATION OF SCADA AND AUTOMATION SYSTEM IN BPME [BAHAGIAN PERKHIDMATAN MEKANIKAL & ELEKTRIKAL], DID There was another round of industrial revolution, when automation was first being introduced to vary industries centuries ago. Things change rapidly especially in process industry. This brings productivity and product quality increase in multiplying manner. As people take the advantages of automation, it slips into every aspect of process control and needless to say Flood Mitigation and Drainage Control system is no exception. The main implementation concept of SCADA and Automation system in DID is to intergrates all drainage infrastructures through SCADA system to perform as systematic, reliable, efficient, and cost saving drainage and flood mitigation management system. Various sub-systems may operate alone or perform as control network when they are integrated. For BPME (Mechanical and Electrical Services Department in DID), sub-systems may include:- a) Dam SCADA b) Drainage structures, pump station and tidal control structures c) Tidal and sea level monitoring d) PTZ IP camera surveillance system


10-2 March 2009

e) Gross Pollutant Trap (GPT) system and automated trash rake SCADA system f) Solar powering system and power backup system The SCADA provides a platform where it can automatically control each sub-system individually with the hydrological algorithm built in for each sub-system, besides collecting meaningful data for supervisory and research purposes. 10.3 CONCEPT OF SCADA AND AUTOMATION SYSTEM

Fig. 10.1 SCADA And Automation System Configuration

The primary purpose of a SCADA system is to provide district engineers and DID personnel with information and control capabilities that are necessary and desirable to properly manage drainage system operation. The information collected and control capabilities are intended to alert the District Engineer to abnormal system condition and allow a timely and effective response to emergency condition that occur in the drainage system. The data collected then will be analyzed by the system and present to District Engineer so that he/she can generate reports and compile reports of the overall system operation for which the District Engineer is responsible.

The data collected also satisfy the need for data from other segments of the DID or other department. For example, the data could be used by local authority in developing the township purpose. Operation personnel and designer would be interested in the operation of prospective equipment after failures or abnormal operation occurs. Maintenance personnel would use the data in regard to the frequency of operation of certain equipment and record for the determination of periodic maintenance required for the facility equipment. Planning personnel would be interested in


March 2009 10-3

the data for determining the required water releases that may be required to meet operational demands of the system. Also, various levels of management would use the data in the form of summary report that provide information on the performance of the overall drainage system in particular area. Drainage infrastructures (like TCG, Pump houses and so on) personnel would use the data for future infrastructure upgrading design. For research purpose, professors and researchers in higher education institutes/universities may interested in the collected data to carry out research works, for example recent Johor flood data may provide researcher good set of data to study the pattern of flood. Because many units within the DID organization may be interested in the data collected by the SCADA system, the needs or desires of all units can be considered during the design of the system.

The ability to schedule and optimize the drainage system is possible with a SCADA system because the data required for the operation of the system are centralized. Scheduling operation can be performed well in advance of implementation, and these schedule operation can be either automatic or manually controlled by the District Engineer. To provide schedule operation, data from all facilities within the system must be collected and the equipment within each remote site must be controllable from master station.

Optimization of drainage system operation is intended to provide the best and most efficient operation of a system during normal operation. Changing system condition are immediately detected and analyzed by the SCADA system and used in the optimization process. For example from the collected water level data, user can fine tune the control level setting to optimize the control of the Tidal Control Gate (TCG).

With all the system data available at the master station, the organization of alarm presentation is extremely important.

Basically, the installed SCADA and Automation system provides features as below: a) System Control

The system provide variety mode of control, including local mode control, manual mode control, auto mode control and remote mode control (for more detail on each mode control explanation, please refer to section 10.5). Auto mode helps to control the system automatically without human attending help to optimize the drainage of the river during the flood.

b) System monitoring The system provides real time and reliable data monitoring for the user to monitor the condition of the system including: i) Drainage and Irrigation infrastructure (TCG, Pump houses, Constant Head Orifice

(CHO), DAM and so on) real time monitoring

ii) Active Alarm Monitoring iii) Flow Trend Monitoring iv) River water level and sea level monitoring v) Tidal and water profile monitoring vi) Historical Events Monitoring vii) Historical Alarms Monitoring viii) Performance Report ix) System published through internet x) System info request through SMS xi) Remote dial in monitoring and control


10-4 March 2009

c) Data Management And Storage

Data plays an extremely important role in SCADA system as mentioned above. The installed system cooperate with a strong data logging, storage and management system that enable the user to analyse the data and fine tune the system from time to time. Basically, installed system provides data management and storage methods as below: (a) Real Time Data Collection Collected data is based on sampling theory where the frequency of sampling is fast enough to represent the real data at site. (b) Frequency Sampling of 1 data Per 5 minutes Frequency of sampling of 1 data in 5 minutes and historical event should be captured during event occur. For example, during gate operation, the system will log the data exactly on the time it open.

d) Data Store, backup, analyze and supervise

The system provides variety of data backup. First, RTU itself may backup the data for 1 year. Meanwhile the server may backup the data for 10 years. Collected data are store in SQL format (or other data storage format) to enable manipulation of the data. Installed system provides user friendly and useful data analysing and supervising tools. The collected data will be automatically analysed by the system and presented in variety format for user to monitor the system and fine tune the system from time to time

e) Critical Event Alert and Handling The installed system may alert the user through SMS if any critical event happened at site so that user can attend to problems on time. This is important to make sure the user get the important critical message on time and react to it.


March 2009 10-5

10.4 SCADA SYSTEM NETWORK TOPOLOGY

Fig. 10.2 Drainage And Irrigation SCADA System Network Topology

Basically the system is divided into 3 major Level functional components which are:

a) Level 1 – Core control of the system which involves all the combination of actuator, water

level sensors, controllers and other related instruments to perform as the front end site control system.

b) Level 2 – Communication medium such as GPRS/GSM/Internet which transfers the data from Level 1 to the server at Level 3 and exchange some of the others control parameter between Level 1 and Level 3

c) Level 3 – Server which stores all the data from Level 1, analyses the collected data and publish them to the public through internet.

10.4.1 Level 1 Level 1 is the front end processing centre which located at site mainly takes care of process control and process data analysis. Level 1 sometime is regarded as IO server. It consists of process controller and data processing unit. IO server provides open interface through standard protocol to the outside world. Through the open standard protocol, transmitting and receiving of data is made possible in varies communication medium through Level 2 such as GSM, GPRS, 3G and internet. Operator is able to receive and request for gate information via SMS. The Components of the Level 1 including:


10-6 March 2009

a) Remote Terminal Unit (RTU) and Controller (PLC) including Digital I/O and analogue Input

- The RTU shall be a high-reliability, industrial grade controller capable of Data Acquisition, Control and Communication. The RTU shall employ special embedded controllers using Programmable Logic Controller (PLC) or processor based design suitable for outdoor environment. The RTU shall, in general, be of a single module type to facilitate ease of field service. It shall be possible and easy to remove the RTU board for replacement, without disturbing the field wiring and without breaking any current loops in the RTU. Web based SCADA shall be provided for Remote Terminal Unit (RTU) at every installed station for remote monitoring, control, setting and data collection. These web based SCADA shall be installed at site but not in main server at control room in order to provide users the most current site information. The minimum features of RTU web based SCADA shall be as follow: i. Shall run on Unix/Linux base OS (operating system) to minimize the hacking problem ii. Shall accessible by any Microsoft Window OS, Unix/Linux OS or even Mac OS base PC or

notebook. iii. Accessible anywhere and anytime by any normal notebook or PC without any special

software. b) GSM/GPRS modem for SMS alert, data request and data transfer

Global System for Mobile Communications Network GSM Network shall be utilized as Main link for communication between Central Monitoring Station (CMS) and Remote Terminal Unit (RTU) through suitable GSM MODEM module. The GSM MODEM Equipment used for the CMS shall be versatile, sensitive, reliable and able to operate for long hours at stand-by mode. The CMS shall be able to communicate satisfactory with the RTU using GSM network even in low signal strength coverage. If the signal strength is too low, an outdoor high gain GSM antenna shall be supplied and installed outdoor with antenna support of sufficient height and shall be safely anchored to the roof top or side of the of the CMS office building. The system shall able to send SMS to users to alert the users during any critical events. Hand phone numbers of these users are configurable and protected by password. Besides SMS alert, the system also needs to provide information about the gate through SMS whenever requested by the users.

c) Site Control Panel

It shall be an IP 65 type floor standing panel or wall mounted similar in construction to L.V boards. It shall be bottom entry of all cable and front access of all components. Control panel shall be weather-resistant & watertight polyester or epoxy coated metal enclosure type IP 65 protection. It shall be made of galvanized 1.5mm steel plate. Double door should be applied for outdoor panel. The panel shall comprise the following:

i. Suitably rated main switch ii. Adequate distribution MCBs with 100% spare capacity. iii. Programmable Logic Control. iv. Battery Operated Clock v. Thermostat controlled anti condensation heater, switch, indicating lights,

push buttons and emergency stop switch. vi. Ventilation fan for panel vii. Lamp and 3 pin plug viii. High voltage area shall be covered with additional protective layer for safety ix. Dual rubber door protection


March 2009 10-7

Double panel should be applied for instrument panel like ultrasonic sensor where the controller should be installed in a PVC panels which are covered by another galvanized instrument panel.

d) Level Sensors

Level sensors are used to detect liquid level. The level measurement can be either continuous or point values. Continuous level sensors measure level within a specified range and are used to know the exact amount of liquid in a certain place and Point level sensors only measures a specific level, generally this is used to detect high level alarms or low level alarms. There are many physical and application variables that affect the selection of the optimal level monitoring solution for industrial and/or commercial processes. The selection criteria include the physical: state (liquid, solid or slurry), temperature, pressure or vacuum, chemistry, dielectric constant of medium, density or specific gravity of medium, agitation, acoustical or electrical noise, vibration, mechanical shock, tank or bin size and shape; and the application constraints: price, accuracy, appearance, response rate, ease of calibration or programming, physical size and mounting of the instrument, monitoring or control of continuous or discrete (point) levels. Level sensor is one of the core instruments in SCADA and automation system. Thus, user must choose correct level sensor to make sure that the system functioning well. Below are some of the sensors that had been chosen to be implemented in SCADA and automation system. i) Point Level Detection of Liquids Only

Magnetic and Mechanical Float Level Sensors The principle behind magnetic, mechanical, cable and other float level sensors involves the opening or closing of a mechanical switch, either through direct contact with the switch, or magnetic operation of a reed. With magnetically actuated float sensors, switching occurs when a permanent magnet sealed inside a float rises or falls to the actuation level. With a mechanically actuated float, switching occurs as a result of the movement of a float against a miniature (micro) switch. For both magnetic and mechanical float level sensors, chemical compatibility, temperature, specific gravity (density), buoyancy, and viscosity affect the selection of the stem and the float. For example, larger floats may be used with liquids with specific gravities as low as 0.5 while still maintaining buoyancy. The choice of float material is also influenced by temperature-induced changes in specific gravity and viscosity - changes that directly affect buoyancy. Float-type sensors can be designed so that a shield protects the float itself from turbulence and wave motion. Float sensors operate well in a wide variety of liquids, including corrosives. When used for organic solvents, however, one will need to verify that these liquids are chemically compatible with the materials used to construct the sensor. Float-style sensors should not be used with high viscosity (thick) liquids, sludge or liquids that adhere to the stem or floats, or materials that contain contaminants such as metal chips; other sensing technologies are better suited for these applications. A special application of float type sensors is the determination of interface level in oil-water separation systems. Two floats can be used with each float sized to match the specific gravity of the oil on one hand, and the water on the other. Another special application of a stem type float switch is the installation of temperature or pressure sensors to create a multi-parameter sensor. Magnetic float switches are popular for simplicity, dependability and low cost.


10-8 March 2009

Conductive (Electrode-Based) Level Sensors

Conductive level sensors are ideal for the point level detection of a wide range of conductive liquids such as water, and is especially well suited for highly corrosive liquids such as caustic soda, hydrochloric acid, nitric acid, ferric chloride, and similar liquids. For those conductive liquids that are corrosive, the sensor’s electrodes need to be constructed from titanium, Hastelloy B or C, or 316 stainless steel and insulated with spacers, separators or holders of ceramic, polyethylene and Teflon-based materials. Depending on their design, multiple electrodes of differing lengths can be used with one holder. Since corrosive liquids become more aggressive as temperature and pressure increase, these extreme conditions need to be considered when specifying these sensors. The technology behind conductive level sensing involves a low-voltage, current-limited power source applied across separate electrodes. The power supply is matched to the conductivity of the liquid, with higher voltage versions designed to operate in less conductive (higher resistance) mediums. The power source frequently incorporates some aspect of control, such as high-low or alternating pump control. A conductive liquid contacting both the longest probe (common) and a shorter probe (return) completes a conductive circuit. Conductive sensors are extremely safe because they use low voltages and currents. Since the current and voltage used is inherently small, for personal safety reasons, the technique is also capable of being made “Intrinsically Safe” to meet international standards for hazardous locations. Conductive probes have the additional benefit of being solid-state devices and are very simple to install and use. In some liquids and applications, maintenance can be an issue. The probe must continue to be conductive. If buildup insulates the probe from the medium, it will stop working properly. A simple inspection of the probe will require an ohmmeter connected across the suspect probe and the ground reference. ii) Sensors for both Point Level Detection or Continuous Monitoring of Solids and

Liquids

Ultrasonic Sensor Ultrasonic level sensors (sometimes called sonic) are ideal for non-contact level sensing of highly viscous liquids such as heavy oil, grease, latex, and slurries as well as bulk solids like cement, sand, grain, rice, and plastic pellets. They are also widely used in water/waste water applications for pump control and open channel flow measurement. The sensors emit high frequency, “ultra” sonic (20 kHz to 200 kHz) acoustic waves that are reflected back to and detected by the emitting transducer. Since the speed of sound in air fluctuates with moisture level and temperature, ultrasonic level sensors are also affected by changing moisture levels and varying temperatures and pressures inside the hopper or container. But when ultrasonic sensors are used in conjunction with humidity and temperature sensors, or a distance reference, correction factors can be applied to the level measurement making the technology very accurate. Turbulence, foam, steam, chemical mists (vapors), and changes in the concentration of the process material also affect the ultrasonic sensor’s response. Turbulence and foam prevent the sound wave from being properly reflected to the sensor; steam and chemical mists and vapors distort and/or absorb the sound wave; and variations in concentration cause changes in the amount of energy in the sound wave that is reflected back to the sensor. Stilling wells and wave guides are used to address some of the above constraints.


March 2009 10-9

Proper mounting is important to ensure that sound waves are reflected perpendicularly back to the sensor. Otherwise, even slight misalignment of the sensor in relation to the process material reduces the amount of sound wave detected by the transducer. In addition, the hopper, bin, or tank should be relatively free of obstacles such as weldments, brackets, or ladders to minimize false returns and the resulting erroneous response, although most modern systems have sufficiently "intelligent" echo processing to make engineering changes largely unnecessary except where an intrusion blocks the "line of sight" of the transducer to the target. Since the ultrasonic transducer is used both for transmitting and receiving the acoustic energy, it is subjected to a period of mechanical vibration known as “ringing”. This vibration must attenuate (stop) before the echoed signal can be processed. The net result is a distance from the face of the transducer that is blind and cannot detect an object. It is known as the “blanking zone”, typically 150mm - 1m, depending on the range of the transducer. The requirement for electronic signal processing circuitry can be used to make the ultrasonic sensor an intelligent device. Ultrasonic sensors can be designed to provide point level control, continuous monitoring or both. Due to the presence of a microprocessor and relatively low power consumption, there is also capability for serial communication from it to other computing devices making this a good technique for adjusting calibration and filtering of the sensor signal, remote wireless monitoring or plant network communications. The ultrasonic sensor enjoys wide popularity due to the powerful mix of low price and high functionality.

Microwave/ Radar Level Sensors

Microwave sensors are ideal for use in moist, vaporous, and dusty environments as well as in applications in which temperatures vary. Microwaves (also frequently described as RADAR), will penetrate temperature and vapor layers that may cause problems for other techniques, such as ultrasonic. Microwaves are electromagnetic energy and therefore do not require air molecules to transmit the energy making them useful in vacuums. Microwaves, as electromagnetic energy, are reflected by objects with high dielectric properties, like metal and conductive water. Alternately, they are absorbed in various degrees by low dielectric or insulating mediums such as plastics, glass, paper, many powders and food stuffs and other solids. Microwave sensors are executed in a wide variety of techniques. Two basic signal processing techniques are applied, each offering its own advantages: Time-Domain Reflectometry (TDR) which is a measurement of time of flight divided by the speed of light, similar to ultrasonic level sensors, and Doppler systems employing FMCW techniques. Just as with ultrasonic level sensors, microwave sensors are executed at various frequencies, from 1 GHz to 30 GHz. Generally, the higher the frequency, the more accurate, and the more costly. Microwave is also executed as a non-contact technique, monitoring a microwave signal that is transmitted through the medium (including vacuum), or can be executed as a “radar on a wire” technique. In the latter case, performance improves in powders and low dielectric mediums that are not good reflectors of electromagnetic energy transmitted through a void (as in non-contact microwave sensors). But the same mechanical constraints exist that cause problems for the capacitance (RF) techniques mentioned previously. Microwave-based sensors are not affected by fouling of the microwave-transparent glass or plastic window through which the beam is passed nor by high temperature, pressure, or vibration. These sensors do not require physical contact with the process material, so the transmitter and receiver can be mounted a safe distance from the process, yet still respond to the presence or absence of an object.


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Microwave transmitters offer the key advantages of ultrasonic: the presence of a microprocessor to process the signal provides numerous monitoring, control, communications, setup and diagnostic capabilities. Additionally, they solve some of the application limitations of ultrasonic: operation in high pressure and vacuum, high temperatures, dust, temperature and vapor layers. One major disadvantage of microwave or radar techniques for level monitoring is the relatively high price of such sensors.

iii) Continuous Level Measurement of Liquids Only

Magnetostrictive Level Sensors Magnetostrictive level sensors are similar to float type sensors in that a permanent magnet sealed inside a float travels up and down a stem in which a magnetostrictive wire is sealed. Ideal for high-accuracy, continuous level measurement of a wide variety of liquids in storage and shipping containers, these sensors require the proper choice of float based on the specific gravity of the liquid. When choosing float and stem materials for magnetostrictive level sensors, the same guidelines described for magnetic and mechanical float level sensors apply. Because of the degree of accuracy possible with the magnetostrictive technique, it is popular for “custody-transfer” applications. It can be permitted by an agency of weights and measures for conducting commercial transactions. It is also frequently applied on magnetic sight gages. In this variation, the magnet is installed in a float that travels inside a gage glass or tube. The magnet operates on the sensor which is mounted externally on the gage. Boilers and other high temperature or pressure applications take advantage of this performance quality.

Resistive Chain Level Sensors

Resistive chain level sensors are similar to magnetic float level sensors in that a permanent magnet sealed inside a float moves up and down a stem in which closely spaced switches and resistors are sealed. When the switches are closed, the resistance is summed and converted to current or voltage signals that are proportional to the level of the liquid. Again, the choice of float and stem materials depends on the liquid in terms of chemical compatibility as well as specific gravity and other factors that affect buoyancy. These sensors work well for liquid level measurements in marine, chemical processing, pharmaceuticals, food processing, waste treatment, and other applications. With the proper choice of two floats, resistive chain level sensors can also be used to monitor for the presence of an interface between two immiscible liquids whose specific gravities are more than 0.6, but differ by as little as 0.1 unit.

Hydrostatic Pressure Level Sensor

Hydrostatic pressure level sensors are submersible or externally mounted pressure sensors suitable for measuring the level of corrosive liquids in deep tanks or water in reservoirs. For these sensors, using chemically compatible materials is important to assure proper performance. Sensors are commercially available from 10mbar to 1000bar. Since these sensors sense increasing pressure with depth and because the specific gravities of liquids are different, the sensor must be properly calibrated for each application. In addition, large variations in temperature cause changes in specific gravity that should be accounted for when the pressure is converted to level. These sensors can be designed to keep the diaphragm free of contamination or build-up, thus ensuring proper operation and accurate hydrostatic pressure level measurements.


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For use in open air applications, where the sensor cannot be mounted to the bottom of the tank or pipe thereof, a special version of the hydrostatic pressure level sensor can be suspended from a cable into the tank to the bottom point that is to be measured. The sensor must be specially designed to seal the electronics from the liquid environment. In tanks with a small head pressure (less than 100 INWC), it is very important to vent the back of the sensor gauge to atmospheric pressure. Otherwise, normal changes in barometric pressure will introduce large error in the sensor output signal. In addition, most sensors need to be compensated for temperature changes in the fluid.

Air Bubbler Level Measurement Systems Pneumatically based air bubbler systems contain no moving parts, making them suitable for measuring the level of sewage, drainage water, sewage sludge, night soil, or water with large quantities of suspended solids. The only part of the sensor that contacts the liquid is a bubble tube which is chemically compatible with the material whose level is to be measured. Since the point of measurement has no electrical components, the technique is a good choice for classified “Hazardous Areas”. The control portion of the system can be located safely away, with the pneumatic plumbing isolating the hazardous from the safe area. Air bubbler systems are a good choice for open tanks at atmospheric pressure and can be built so that high-pressure air is routed through a bypass valve to dislodge solids that may clog the bubble tube. The technique is inherently “self-cleaning”. It is highly recommended for liquid level measurement applications where ultrasonic, float or microwave techniques have proved undependable. Numerous level sensing devices incorporating numerous technologies are available or can be adapted for a wide variety of applications. In addition to chemical compatibility, understanding and evaluating how the physical and electrical characteristics of the process material, affects the operation of a sensor or sensing technology will assure trouble-free operation and long sensor life.

e) Doppler Flow meter

The compact Doppler flow meter is a two-beam, horizontally oriented flow meter designed to obtain high accuracy velocity data at ranges from 1 to 300 meters, utilizing 1 to 128 cells of data. By leveraging Doppler flow meter, it allows to obtain unmatched data quality, even in low velocities and complex flows, where a single cell cannot provide enough information. The Doppler flow meter is ideally suited for use in rivers, streams, estuaries, open channels, and ports and harbors. The Doppler flow meter accuracy and versatility are ideally suited for: • Streams and Rivers -

Obtain high accuracy velocity data for use in computing discharge. The unit includes an accurate acoustic level sensor and pressure sensor to determine stage as well.

• Open Channels - Obtain accurate velocity data for pacing water quality samplers.

• Estuaries - Measure the complex currents for environmental monitoring or circulation model calibrations.

• Ports and Harbors - Monitor currents to provide accurate information for mariners.


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10.4.2 Level 2 Level 2 is the communication medium which provides communication platform for Level 1 and Level 3. Telecommunication plays an important role in SCADA and Telemetry system. Selection of communication method for particular SCADA system depends on:

• Reliability of selected communication method • Availability • Cost • Future extendable

Basically, communication in SCADA system divided into 2 categories as below:

a) short distance/Local communication which mostly involve with communication between site instruments like sensors, RTU, web cam and so on.

b) Long Distance communication which involve with communication between RTU and Master Workstation or Server where the site data is transfer back and telecontrol from workstation and SCADA server.

Communication method for short distance/local communication implemented including: a) Serial Communication

Serial communication like RS232, RS422, RS 485, Modbus and profibus are common serial communication protocol to link with instrument like water level sensor, flowmeter, drive, rain gauge, water quality sensors, inverter, and controller.

b) Voltage/ampere signal cable Voltage/ampere signal communication method is one of the most conventional communication method in automation and SCADA control system. For implementation in DID SCADA system, DID only allowed low voltage and ampere implemented for this purpose. (normally VDC 12 – VDC 30 for voltage and 4mA to 20mA for ampere). This method especially implemented in actuator control signal and pump control signal like start, stop, trip and so on. c) Coaxial Cable This communication method is mostly implemented in video signal communication, especially in CCTV. Anyway, DID nowadays less implements CCTV compare with Web Cam due to analogue signal from CCTV is hard to be transfered through internet for long distance monitoring and the highest resolution of CCTV can only achieve 800 x 600 pixel although implementation of CCTV is cheaper than Web Cam. d) Fiber Optic Fiber Optic is one of the most advance and effective communication method in wire/cable communication. Anyway, due to it’s cost and complicated construction during cable lying, most of the time it only apply in short distance communication.


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e) Ethernet

Ethernet, especially ethernet LAN has always been chosen for communication between local controller (for example in between RTU (Remote Terminal Unit) and PLC (Programmable Logic Controller)) due to its speed and reliability. Sometime, it is also used to communicate between RTU and web cam at site.

f) Wireless Radio

Radio communication is one of the oldest communication method in SCADA communication. Radio can be used in both short distance and long distance communication. Anyway, due to reliability issue especially interference during bad weather, radio communication had became less popular communication method as more and more reliable new wireless communication method in market. g) Wireless LAN Wireless LAN communication is one of the most popular and reliable communication for short and medium distance communication method. Example of successful implementation case can be found in S18, Penang Urban Drainage Pump Expert system where wireless LAN communication link up trash screen and Pump house with distance more than 100m. Another example in PA (Pintu Air) Sg Klebang, Melaka where wireless LAN link up 2 units of PTZ Web Cam with RTU.

Communication method for Long distance communication implemented including: a) PSTN (Public Switched Telephone Network)

PSTN is one of most conventional communication method implemented in SCADA communication due to ability and cost effective. Anyway, after few years implementation in DID SCADA communication, DID discovers that most of the PSTN communication faces surging problem, especially for lightning surge.

b) GSM Global System for Mobile communications (GSM) is the most popular standard for mobile phone in the world. GSM is used by over 2 billion people across more than 212 countries and territories. Implementation of GSM communication in SCADA communication is very similar to PSTN communication where communication only happened in one to one method with communication Modem. Thus, most of the SCADA system in DID still implement GSM for remote control due to security purpose. c) GPRS General Packet Radio Service (GPRS) is a Mobile Data Service available to users of Global System for Mobile Communications (GSM) and IS-136 mobile phones. GPRS data transfer is typically charged per kilobyte of transferred data, while data communication via traditional circuit switching is billed per minute of connection time, independent of whether the user has actually transferred data or has been in an idle state. Popular communication method to transfer the data from RTU to Server through internet. (Even 3G is better than GPRS, but availability of 3G in Malaysia is limited.)


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d) EDGE Enhanced Data rates for GSM Evolution (EDGE) or Enhanced GPRS (EGPRS), is a digital mobile phone technology that allows increased data transmission rates and improved data transmission reliability. Although technically a 3G network technology, it is generally classified as the unofficial standard 2.75G, due to its slower network speed. EDGE has been introduced into GSM networks around the world since 2003, initially in North America. EDGE can be used for any packet switched application, such as an Internet connection. e) 3G High-Speed Downlink Packet Access (HSDPA) is a 3G (third generation) mobile telephony communications protocol in the High-Speed Packet Access (HSPA) family, which allows networks based on Universal Mobile Telecommunications System (UMTS) to have higher data transfer speeds and capacity. DID starts to implement 3G in SCADA communication in recent years. Anyway, due to 3G coverage over Malaysia is still limited, implementation of this communication method is still not popular. f) Broadband Streamyx is the one of the most popular internet broadband service provider in Malaysia which had been wisely used by DID in recent year for SCADA communication. It is mostly implemented in communication between SCADA server with RTU or SCADA client. For SCADA server a fix IP needs to be implemented so that RTU at each site can update the data to server from time to time. Anyway, the server can also function without fix IP by using redirecting from others server so call “No IP” server.

Global System for Mobile Communications Network GSM Network shall be utilized as Main link for communication through suitable GSM/GPRS/3G MODEM module due to their reliability, role against lightning strike and speed of transmition. For network Camera, streamyx shall be used as a main communication media between installations sites Master SCADA Server at Level 3. The modem must also be cooperated with alert system to send SMS to the users during critical event and reply the user with latest site information whenever the user request through SMS. In other worlds, only 1 GSM/GPRS/3G modem allowed to be installed at 1 site. The GSM/GPRS/3G MODEM Equipment used shall be versatile, sensitive, reliable and able to operate for long hours at stand-by mode.

As a result of fast technological advancement in the electronic/communication fields, the above mentioned systems will be expected to be replaced with the latest technology in a short period, which the users of this manual have to be aware of. 10.4.3 Level 3 Level 3 content SCADA Server which usually placed at the administration office is configured to upload data from Level 1 at scheduled interval. In this case, all remote sites data are collected and store in the server through Level 2. The server also provides monitoring information for each site. The main tasks of Level 3 are presenting gate information and data storage. It chunks data, displays information; views live image, present report and achieves history data. Lastly additional viewing client is allowed to login into site front end processor with permission from authority.


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The master station (INFOMECH) equipment performs the function of collecting data from remote sites at Level 1, analyzing the data, presenting the data in a suitable format for further action and control the remote site through parameter passing. As mentioned before, with the hydrological algorithm built in, the server will scan through the data from each site and carry out further control on particular station at Level 1 within the network. For example, Tidal Control Gate which located at the coaster area will open earlier if the water from DAM is released. At the same time, with the sea tidal index calculation algorithm built in, the TCG will inform during high tide where the DAM need to stop to release water to prevent ‘Internal Flood’. It also provides a set of control setting and remote control for the users where user can remote log into particular site for remote control and setting. Result from data analyzing also presented in variety of format for users information and published to the public through internet. Collected data will be stored in INFOMECH for more than 10 years. (The target is to store the data more than 20 years in order to collect 19 years full cycle of tide characteristic.) System also provide 1 to 1 remote dial in monitoring, where the user can dial in remotely for remote control and monitoring to each remote station at Level 1 using whatever PC or Notebook with whatever Operating System (only internet browser required) anytime and anywhere as long as user have password to do so.

No reframe of number of clients with condition of one client login in at a time. Viewing client can be located just next to control panel at site or located as far as to the other side of the globe as long as internet is available. In term of functionality of proposed the tidal gate SCADA system. It is summarised into items as below:-

• System monitoring • Data management/analyze • Data Storage

(Please refer to section 10.3 for detail explanation on system monitoring, data management/analyze and data storage) 10.5 TIDAL CONTROL GATE (TCG) OR TIDAL CONTROL BARRAGE SCADA AND AUTOMATION SYSTEM Basically, automation and SCADA system shall be able to provide the following gate operation:-

a) Drainage control profile and Irrigation Control Profile b) Automatic control mode c) Remote control with password protected d) Manual control at control panel e) Local control at actuator

10.5.1 Drainage and Irrigation Control Profile

Watergate system is designed mainly for two purposes, irrigation and drainage purpose. In irrigation mode, the system will maintain water level at certain irrigation level for irrigation purpose and prevent the sea water to flow into the river. Meanwhile in drainage mode, the system will close the gate during high tide to prevent the sea water flow into the river and the system will open the gate to drain out the upstream water when tide go down.


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The system shall build in 2 control profiles for installed system namely Irrigation mode and Drainage mode. In drainage mode, the system will drain out the water automatically as the tide low, and close the gate as the tide going high. In irrigation mode, the system will reserve the water at setting level for irrigation level and drain out the water as the level achieve the setting level during tide low. The system shall close the gate as the tide up or the water level achieves irrigation low level. These two modes of control operation are totally contrary to one another. If one sets the control to irrigation mode, the control system keeps the water. But if one sets the control to drainage mode, the control will flushes the water instead. A good Watergate system must able to handle both of these controls in the same system. Thus, the consultant team proposed that the system should build in both of these two modes for users convenient. Users only need to change the setting on the control panel and the system will start to perform that particular mode of control without any modification or changes in the system. This is what so call user friendly Watergate control system. 10.5.2 Automatic Control mode The system shall be able to detect the high tide and low tide and prevent the sea water to flow into river. However, the system shall intelligent enough to open the gate as upstream level is higher than downstream during high tide and at the same time prevent the sea water to flow into the river. Control algorithm of automatic control shall be intelligent enough to make accurate decision on gate control. Gate shall not open and close too frequent to avoid actuator from burn out. The system shall be intelligent enough to take accurate tide level and not affected by any interference like boat’s wave. 10.5.3 Remote Control and Remote Monitoring Mode

The system shall able to provide remote control mode with password protected. Users shall be able to login to system remotely at any moment and any location using any notebook or any PC without any special software to do remote monitoring and remote control as long as users have username and password to do so. (For remote control, multi layer password shall be applied for security purposes). User shall be allowed to access remote control mode from MMI through web server OR directly from RTU web SCADA. 10.5.4 Manual Push Button Control Mode

The system shall provide manual control mode where users can only control the gate at site by pressing open or close button at the panel. Manual control mode shall have higher priority than auto and remote control for security purposes especially during maintenance. 10.5.5 Local Control Mode

The system shall provide local control at actuator and local gear box. There are two local control modes available for the system includes:

a) Local actuator control mode whereby operator may lift up the gate by select the actuator to actuator local control mode at actuator and push on open button to open and close button to close the gate. Operator may also push on stop button to stop the operation of the actuator.

b) Local Manual Control mode whereby operator may open or close the gate by turn on manually on the handwheel provided at actuator or gear box.


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10.6 PUMP EXPERT SYSTEM

The Pump Expert System and SCADA System that was developed is actually a combination between a Supervisory Control And Data Acquisition System (SCADA) and Expert System. Besides providing as a SCADA solution, the DID Pump Expert System intends to help the DID engineers to make better decisions on supplying water to irrigation scheme and provide useful advice, thus fills the knowledge gap between the expert and the user. Pump Expert System may implement in both irrigation and drainage system As precision farming requires irrigation amounts to be precisely measured and monitored, the expert system can provide an efficient way of improving the irrigation system operation. The project was undertaken to develop a pump expert system in order to make improvement in the operation of irrigation water management with a SCADA as a Decision Support System (DSS). In drainage control, the pump expert system may help to control the drainage of water especially during high tide and heavy rainfall situation. With the expert automation algorithm built in, the system will always optimize the system in term of number of pumps running, capacity of drainage as well as consumption of electricity or fuel. Besides, the Pump Expert System (PUMPX) was designed to diagnose the causes of pump operations problem in the command area of an irrigation system. The system is intended to identify casual factors that are responsible for poor functioning of an irrigation system. The benefits that can be derived from the pump expert system include fast response and computerized control of water supply, easy and efficient operation, easy and low cost maintenance, and the system is web enabled. Successful implementation of the project could eliminate labor shortage problems, and ease operational procedures. A Pump Expert Automation and SCADA system must take care a lot of issue including:

a) Pump Start Stop sequence b) Pump Duty Time Accumulation and Maintenance c) Real time historical data logging for analyze purpose d) Efficient drainage control e) Pump duty performance and total volume discharge f) Electricity Energy saving

10.6.1 Pump Start Stop Sequence One of the most significant problems in pump control system is pump start stop sequence control. In normal operation, pump running is based on the level of water in retention pond. The pump will be turned on one by one according to the level. In other words, not all the pump will be switched on in one operation section. In this case, some of the pump will be jammed due to less of operation. Thus, a pump rotating start stop system must be applied to the system in order to avoid the pump jammed problem. In conventional system, pump rotation is based on the hardwiring control, where the control will start from first pump towards last pump initially. The system then will reset the sequence as the water level drop to low level. After reset, in next control section, second pump will run first towards the last and the first pump will be the last pump which running in that control section. The system will keep continue the rotation as long as the system is reset after each control section. Anyway, problem comes when the water level doesn’t go down to reset level due to sentiment problem. The system will keep running in that particular sequence of control and the pump jammed problem may occur later.


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Another critical issue comes up during pump trip. For example when control sequence come to particular pump, and that pump tripped in the same time, the system will not jump to next pump but waiting the water level rise up to next pump trigged level. Then only the next pump will run. This is very dangerous during raining season where the late start of pump may cause the flood in upstream. Aware of this, Pump automation system shall be built in an intelligent pumping rotation system to control the pump. Ultrasonic water level will be installed to detect the level of the water in place of probe or level switch. This is due to the reliability of ultrasonic sensor is far more than probe and level switch. Beside, measuring range of ultrasonic sensor can be changed through software setting easily. An AI control algorithm also built in to take cares the pump run sequence. The system will remember the operation of each pump and start up the longest stop time pump each time and following by the queue. The system will also automatically jump over to next sequence pump if whenever the system finds the duty pump is tripped or in maintenance.

10.6.2 Pump Duty Time Accumulation and Maintenance Heavy duty of the pump requires periodically maintenance to extend the life time of the pump. Conventional system doesn’t have any figure to monitor the duty time of each pump. Maintenance for particular pump cannot be carried out on time. This may reduce the life time duty of particular pump. For this, Pump Expert System shall be built in special software that can accumulate the run time for each pump. System will also alert the users whenever the particular pump accumulated run time achieve the maintenance goal. 10.6.3 Efficient Drainage and Irrigation Control When we study the pumping system carefully, we may find that most of the time pump drainage capacity is enough to drain out the water during heavy rain. Control level plays a very important role in this case. Users need to set a good range of control level to make sure the pumping system control according to real situation needs. Conventional system is very difficult for users to justify what is the best control range of level for particular pumping system due to no data logging for every control section. Thus, pumping expert shall provide a lot of valuable data like trending logging, control data logging events/alarm logging and others information. From this information, users can sort out the best control range level for particular pumping system and this may certainly help to improve the efficiency of the drainage control.

Same case in irrigation pump expert control, with availability of water supply level and water flow rate, system manager may sort out the best water supply control to optimize the water supply for particular irrigation scheme. 10.6.4 Pump Duty Performance and Total Volume Discharge Pump Expert system shall provides varies of performance report of pump duty like volume daily, weekly, monthly water level report, volume discharge report, duty time report and others. The system also calculates out the total volume discharge for each pump. Throughout these report the users can estimate total waste water from particular area, pump capacity, total rain fall and others important data. These data are very important for city development and future town planning. 10.6.5 Electricity Energy Saving One important concern in pumping system is electricity energy usage issue. Heavy duty of the pump requires high usage of electricity power. Every month, users need to pay thousands of ringgit for electricity. This is a burden to users especially the non-profit government body.


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Moreover, according to electricity theory, the system consumes much higher power during each start up period. In others word, if the system start/stop too frequent it may definitely cause a lot of electricity wastage. In conventional system, since the system using hardwiring control, frequent start stop is possible due to gray area in bourdon line of control level. Sudden change of water level, some time will also cause two or three pump to run in the same time. This may cause electricity usage penalty. Aware of this, Pump Expert System shall be built in a control algorithm that is able to take cares this problem. The system will intelligently decide when the best time for particular pump to run. A hysterics is built to avoid the system to start stop frequently. AI control algorithm applied to the system also enabled the system to take care the sudden change based on previous data and control. 10.6.6 Components of Pump Expert System An expert system normally compose of a knowledge base (information, heuristics, etc.), inference engine (analyzes knowledge base), and end user interface (accepting inputs, generating outputs). The Pump Expert System consists of the following components and sub-components; Remote Terminal Unit, Data Acquisition Module, Control Module, Touch Panel Operators Interface, Power Supply, Lightning Protection Unit (LPU), Sensors , Voltage (R,G,B), Power factor meter and Current Transducers (R,G,B), Ultrasonic Water Level Sensor (Upstream, Downstream), Open Channel Flow meter (Outflow), Pump Vibration Sensor (for each pump), Communication System, SCADA Server / Central Monitoring Station (CMS) which functioning as mentioned in section 8.3 above. To further improve the system, pump expert also built in Maintenance Management Software (MMS) which may work as below:. Maintenance Management Software (MMS) The Maintenance Management System (MMS) is capable of producing computerized and comprehensive, state of art maintenance management with user selected date and parameters. The MMS is capable of producing the following reports (depends on available of signal at each pump houses:

a) Comprehensive vibration status report (daily, monthly summary) b) Pump running duration report (daily, monthly summary) c) Current consumption report (daily, monthly summary) d) Pump efficiency and losses report (daily, monthly summary) e) Alarms report (daily, monthly summary) f) Pump power usage report (daily, monthly summary) g) Electric bill usage report (monthly based on manually keyed–in values) h) Breakdown report (daily, monthly summary)

The MMS is a simplified Expert System and two way communication system where it can perform the following mode:

a) Accept Web Online Fault Reporting after user login as authorized user. The MMS will broadcast the fault report by SMS to all the maintenance staff’s mobile phone as listed in the MMS User Page

b) Accept SMS Fault Reporting from any maintenance staff mobile number. The MMS will broadcast the fault report by SMS to all the maintenance staff’s mobile phone as listed in the MMS User Page

c) Accept Web Online Repair/Maintenance Report after user login as authorized user. The MMS will broadcast the Repair/Maintenance Report by SMS to all the maintenance staff’s mobile phone as listed in the MMS User Page

d) Automatically SMS summary of Daily Pump Start/Stop Operations to top level management staff


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e) Automatically SMS Maintenance Reminder to maintenance staff f) Automatically SMS Spare Part Replacement Reminder to maintenance staff

10.7 INSTALLATION OF SCADA SYSTEM Below are the installations involved for the SCADA System: a) Installation of Automation System b) Installation of SCADA System

10.7.1 Installation of Automation System Automation system at site is an integration of instruments like actuators, level sensors and others with RTU (Remote Terminal Unit) to perform as an automatic TCG operation system besides logging data for SCADA system. Beside, during any critical event like power failure the system will also alert the user through SMS. 10.7.2 Installation of SCADA System SCADA (Supervisory Control and Data Acquisition) is the core of the system. It works closely with automation system to perform a better automation and SCADA control system. Installation of SCADA system including: a) Installation of SCADA Server b) Installation of Server communication (GPRS, Fix IP) c) Installation of RTU web base SCADA d) Installation of SCADA workstation e) Installation of Portable Retrieval Unit 10.8 TESTING AND COMMISSIONING Site Test of all Equipment after installation, and provide certified records, in triplicate, of the results. Installed system shall ensure smooth operational of the entire system installed for minimum 2 weeks prior to Pre-Test. Each component device shall be exercised for the full extent of its capability, from minimum to maximum and under automatic control, where such is applicable, as well as manual operation. Pre-test should be carried out by contractor before real testing and commissioning carried out by DID officer. Testing procedure, testing form, testing schedule, necessary equipment and instruments shall be prepared for the Testing and Commissioning. Installed system shall ensure smooth operational of the entire system installed for minimum 3 months prior to Testing and Commissioning. Appropriate documentation of all equipment and system submittal record, installation and operational verification for all devices shall be provided. This documentation shall be consolidated in a Commissioning and Closeout Manual. 10.9 TRAINING REQUIREMENTS IN IMPLEMENTATION OF ICT AND ICA (INFORMATION & COMMUNICATION TECHNOLOGY/APPLICATION) SYSTEMS Practical training should be carried out for each site and a large scale overall training. This will comprise Engineers and Technician who will ultimately be responsible for the operation and maintenance of the system. The training course shall comprise the following lectures and practice. The training should be delivered in two level:

a) Training for management level b) Training for operation and maintenance level


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Outline of the principles of the hardware and software as following:

a) Electrical and electronics fundamentals b) Communication equipment system; methods and mechanism c) Data Acquisition System d) PLC/RTU and Interfacing e) Gates Operation f) Setting of actuator g) Sizing and selection of actuator h) Instrument methodology; water level sensor i) Error prevention, detection and correction j) Software Programming and Operating System k) Data Management l) Installation and operating of each equipment m) Operation, Maintenance and repair n) Networking and System Integration.

The outlines of the ‘on site training’ as below but not limited as following:

a) Calibration of water level sensor and any other instrument installed at site b) Setting mechanism for control panel c) Setting of actuator d) System maintenance e) Operation and maintenance

10.10 FACTORY INSPECTION AND TEST The purpose of the factory inspection is to establish whether the manufacturer has the conditions for manufacturing the electrical product according to the relevant requirements. Factory inspections are consisted of the initial factory inspection (carried out simultaneously with the certification test) and the regular factory inspection. Initial factory inspection is carried out to assure the manufacturing system can supply the products submitted for registration at a stable pace and a high degree of quality. Regular factory inspection is performed for the purpose of follow up. Initial factory inspection should be applied to equipments like actuators, Sensors, Control panels and controllers. Meanwhile, regular factory inspection should be carried out for SCADA software development and maintenance. 10.11 QUALITY ASSURANCE The quality assurance review shall be conducted independently. The contractor shall appoint the competent personnel with both agreement of S.O and contractor. The personnel shall have minimum 10 years solid experience in handling quality assurance site supervision of gate automation system and any relevant field of expert. Reviewer with DID experience will be an advantage. The contractor shall ensure the tasks but not limited of the following are being carried out by the assigned personnel: a) to ensure the that all construction activities comply with approved drawings and

specifications b) to ensure that field decisions are based on sound engineering and environmental

considerations c) to ensure communication between the contractor, consultant and DID regarding any

changes or modifications incorporated d) to ensure that all inspected and relevant activities are properly documented. e) shall be at site and ensure that all installation activities according to specification


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f) shall ensure all electrical installation are relevant and comply with international standard. g) shall be at site during pre-test and Testing and Commissioning and submit test report. h) review and propose appropriate test and checklist for pre-test and Testing and

commissioning. i) shall review all manuals (which include operation & maintenance manuals) and training

documents. 10.12 MAINTENANCE OF SCADA SYSTEM Maintenance needs to be carried out to make sure the system always in tip-top condition. Contractor should carry out schedule of maintenance during warranty period for three (3) years (Once every 3 months) after successful commissioning of the system. The contractor shall prepare `Schedule Maintenance Plan’ every quarterly during the warranty period and the cost shall be included in the tender. A maintenance report specifically on every site should be prepared after every maintenance services. Maintenance carried out should at least cover items as below: a) Main Power Supply b) Secondary Power Back up c) Gate Operation (Manual, Auto, Remote, Local and Emergency Stop) d) Water Level and Level Sensor e) Touch Screen Function f) Emergency Alert g) Actuator Functioning and setting h) Info Request/Communication Testing i) SCADA server maintenance j) SCADA workstation maintenance k) Remote Dial in Monitoring and Control l) Control Panel Cleaning and Maintenance