Jurutera June 2013

7/22/2019 Jurutera June 2013

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Mechanical Engineering


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APPLICATION Slope Protection Embankment Stabilization Housing & Road Project Other Civil Engineering Application

APPLICATION Bridge Abutment Land Reclaimation Housing Development & Temporary

Embankment Other Civil Engineering Application


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LAFARGE CONCRETE (MALAYSIA) SDN BHD (95483-H)2, Jalan Kilang, 46050 Petaling Jaya,

Selangor Darul Ehsan, Malaysia.

Tel : (603) 7787 2000

Fax : (603) 7781 7675 / 7787 212 9

www.lafarge.com.my

Agilia is a new horizon for self-compacting and self-leveling concrete that spreads

eortlessly. The new concrete technology used in Agilia allows for placing without

difficulty , providing excellent quality concretes with superior surface finishes.

Requiring no vibration , Agilia moves easily through highly congested reinforced

areas , with no bleeding and segregation. It is robust and esthetically pleasing.

Agilia gives flexibility on worksites at all levels, for all types of applications

including foundations, architectural, horizontal and vertical structures.

LAFARGE CONCRETE (MALAYSIA) SDN BHD (95483-H)2, Jalan Kilang, 46050 Petaling Jaya, Selangor Darul Ehsan, Malaysia.

Tel : (603) 7787 2000 Fax : (603) 7781 7675 / 7787 2129

www.lafarge.com.my


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June 2013 JURUTERA | 3

JulyElectronic Engineering

OctoberYoung Engineers Section

August

Mentoring Engineers - The Way Forward

November

Oil, Gas & Mining Engineering

SeptemberChemical Engineering

DecemberFacilities Management

JURUTERA MONTHLY CIRCULATION: 28,000 COPIES

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CONTENTS

COVER NOTE

New Challenges for Mechanical Engineers .............................................................5

COVER STORYMechanical Engineering: Its Vital Role and Prospects .............................................6

PRESIDENTS CORNERProgressing Towards a More Dynamic Culture Within IEM

by Ir. Choo Kok Beng .............................................................................................12

HISTORY OF IEMThe First Two Sessions of IEM Council (1958-1960) .............................................14

FEATURE ARTICLEEnergy Savings From Axial Fans ...........................................................................16

$IQLW\/DZV,QWHUSUHWDWLRQVDQG$SSOLFDWLRQV)RU&HQWULIXJDO3XPSV ..................20Product Development Through The Use of Rapid Prototyping ..............................28

ENGINEERING DIGEST 30

FORUMS7th International Conference on Cooling and Heating Technologies in 2014

(ICCHT 2014) .........................................................................................................33

Retreat and Brainstorming Workshop ....................................................................35

Application of Plastic Pipes in The Plumbing Industry ...........................................36

,PSURYLQJ,(0V/LQNDJHVZLWK7KH0LQLVWULHV........................................................36

The Engineering Club Outreach .............................................................................37

FROM THE DESK OF PEMANDU

Government Transformation Programmes Corporate Integrity Pledge .................38

PINK PAGEProfessional Interview ............................................................................................40

BLUE PAGE0HPEHUVKLS/LVW.....................................................................................................41

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COVER NOTE


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COVER STORY

| JURUTERA June 20136

Mechanical Engineering: Its Vital Roleand Prospects

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MANY COUNTRIES HAVE BEEN PROMOTING

RENEWABLE ENERGY AND ENERGY

EFFICIENCY. WHAT IS YOUR VIEW ON THEPOTENTIAL DEVELOPMENT OF RENEWABLE

ENERGY AND ENERGY EFFICIENCY IN

MALAYSIA?

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E N V I R O N M E N T A L

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IS THE POTENTIAL

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SOCIETY IN THE

COUNTRY?

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THERE HAS GENERALLY BEEN AN INCREASE

IN THE NUMBER OF INCIDENTS ON ENGINEERING

SAFETY AND QUALITY RECORDED IN RECENT

YEARS. HOW CAN MECHANICAL ENGINEERS

RENDER A HELPING HAND TO MITIGATE THESE

INCIDENTS?

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THERE ARE CRITICS WHO SAY OUR COUNTRY IS

KNOWN FOR ITS FIRST WORLD FACILITIES, BUT

THIRD WORLD OPERATION AND MAINTENANCE

(O&M) PRACTICES. WHAT IS YOUR VIEW ON

THIS STATEMENT?

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IN CONCLUSION, WHAT IS YOUR OPINION

ABOUT THE MECHANICAL ENGINEERING

PROFESSION, HAVING BEEN A PART OF IT

THROUGHOUT YOUR ENTIRE CAREER?

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IN YOUR OPINION, WHAT IS GENERALLY

LACKING IN MOST OF THE MECHANICAL

ENGINEERS IN MALAYSIA AND HOW CAN THAT

BE IMPROVED?

Ir. Fam::KHQLWFRPHVWRWUDLQLQJDQGVHOIGHYHORSPHQWPRVWPHFKDQLFDOHQJLQHHUVDUHVWLOOSUHWW\PXFKFRQQHG

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HA S YOU O ON

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13/48

Date: 8-9 July 2013

Venue: Summit Hotel USJ, Selangor

Main Speaker: Prof. Dr. Nor Azazi Zakaria

Fee: RM 250/day/person (RM50 discount for early bird)

Kindly contact us for more information regarding the workshop.

Date and venue for Johor and Sabah workshops to be confirmed.

Topics:

Venue: Summit Hotel USJ, Selangor

Main S eaker: Pro . Dr. Nor Azazi Zakaria

Date: 8-9 Jul 2013 To ics:

MSMA 2 Workshop:

BEM Approved

CPD HOURS: 14Ref No: IEM13/PP/027/W

MES-GeoF MES-BioFDMES-SurveyMES-Road EW3D DraNet SewNet PondCAD

We also offer Individual Modules like:

LoopWinPlus

Road & Highway

-Horizontal & vertical alignment design

-Junction design

-Cut section and detailing needed for submission

-Based on REAM guideline

Earthworks

-Digital Terrain Method and Grid Method for volume calculation

-3D visualization before and after development

-Auto sloping and retaining wall design

-Auto balancing between cut and fill volume

Drainage

-Follows MSMA 2 guideline

-Auto proposes sump invert level, cascading drain, dimension &

gradient.

-Auto generates output needed by JPS

Sewerage

-Auto calculates Population Equivalent (PE)

-Auto proposes manholes invert level, pipe diameter, gradient

& drop manhole.

-Auto generates output needed by IWK

Urban Stormwater Management (MSMA 2)

-Rainfall IDF

-On-site Detention (above & below ground)

-Detention Pond

-Rainwater Harvesting Tank

-Sediment Basin (wet & dry)

Water Reticulation

-Hardy-Cross Method and Hazen-Williams Formula

-Looping & branching design for peak flow & fire flow

-Schematic diagram with pump, hydrant, valve and etc

MiTS 1.2

MES Infra Integrated Total SolutionMiTS 1.2

werageS

Synchronize design changes across a single model

and automatically update between Earthworks,

Storm Drainage System, Sewerages System, Water

Reticulation System & Road Design.

Pipe Clash Checking between Water, Sewerage

& Storm Drainage system to resolve conflicts.

Deliver consistent multi-disciplinary design calculation,

drawings & construction documentation.

Better visualization, more accurate design, enjoys

better coordination.


14/48

PRESIDENTS CORNER


Progressing Towards a MoreDynamic Culture within IEM

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by Ir. Choo Kok Beng

HELP US TO PROVIDE BETTER SERVICES TO YOU AND

TO THE FUTURE GENERATIONdt/D&

TOTALRM 2,823,531.20

(ANOTHER RM 9,326,468.80 IS NEEDED)

CONTRIBUTIONS TO

WISMA IEM BUILDINGFUND

RM 2,182,029.20 fromIEM Members and

Committees

RM 641,502.00 fromPrivate Organisations

IEM ENGINEERING WEEK 2013

7 - 15 September 2013Organised by: /tt^

^t^D

Various activities will be organised by IEM HQ

and Branches

IEM Engineers Run 2013

7 September 2013

Jalan Timur, Petaling Jaya

/D//

/E/y^

One Utama, Bandar Utama


15/48

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16/48

HISTORY OF IEM


THE FIRST TWO SESSIONS OF

IEM COUNCIL

AT the IEM Inaugural Meeting held on 1 August 1958 atNo. 23, Perak Road, Kuala Lumpur, nine engineers were

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organisation, The Institution of Engineers, Malaysia (IEM).

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hard to lay the foundation of the Institution. During the

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nine meetings to discuss and decide on important matters.

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17/48

Industrialplugs and

sockets.

Creating connections. Maintaining connections.

MENNEKES

Elektrotechnik GmbH & Co. KG

10, Jln Lep 7/26, Sek 7

Tmn Lestari Putra, Bdr Putra Permai

47110 Seri Kembangan, Sgor, Msia

Phone +60 (3) 8957 4487

Mobile +60 12380 6996

www.MENNEKES.de


18/48

FEATURE

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ENERGY consumption has become an important

consideration to every individual globally. The word

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topics related to energy. As the development around us

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SURSRUWLRQDOO\LQFUHDVHV(IFLHQWHQHUJ\XVDJHZLOO LQWKHlong run reduce the burden on our pockets. The business

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In my previous article pertaining to the jet fan and

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regarding the replacement of conventional ducting design

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represents a positive step in recovering the energy losses

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Often the case is that fan systems directly support production

processes. Hence, many fans operate continuously but

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consumption and substantial annual operating costs.

Another investigation has been carried out on the main

fans in a ventilation system. Among the many types of fans

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fan drives the air through the impeller in approximation of an

axial direction. The axial fan utilises blades that force air to

move parallel to the shaft around which the blades rotates.

Owing to its cost effectiveness and multi-functional nature,

the axial fan has been widely adopted in the industrial,

commercial, consumer, institutional, and residential

applications. In a typical car park ventilation system, these

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fans.

Axial Fans

without Guide Vane

Axial Fans

with Guide Vane

Basement Type of Fan Total

number

of fans

Total power consumption

(KWh) per year

Annual electricity

cost (RM)

Total power consumption

(KWh) per year

Annual electricity

cost (RM)

basement

1

supply and

exhaust fan

8 80,179.20 25,857.79 73,764.90 23,789.17

basement

2

supply and

exhaust fan

12 171,417.60 55,282.18 157,704.20 50,859.60

7RWDO&RVWZLWKRXWYDQH 81,139.97 7RWDO&RVWZLWKYDQH 74,648.77

Savings for Basements 1 and 2, per year (RM) 6,491.20

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The energy consumption of these fans was investigated

at two basement car parks of a 10-storey and 14-storey

RIFH EXLOGLQJ $Q HQKDQFHG JXLGH YDQH GHVLJQ ZDV

installed downstream of the ventilation main fans for a better

HIFLHQF\(FRQRPLFDOFRPSDULVRQZDVPDGHEHWZHHQWKH

existing fan models and the enhanced model with guidevane by measuring the power consumption in KW. The

guide vane used in this investigation is of the adjustable

type. Table 1 shows the compilation results of the total power

FRQVXPSWLRQ .:K DQGWKH DQQXDO HOHFWULFLW\FRVWLQJIRU

the existing fan model on a normal mode of operation. The

DQQXDOHOHFWULFLW\FDOFXODWLRQ(TZDVGRQHEDVHGRQD

12-hour, 6 day per week operating duration.

7KHJXLGHYDQHZDVGHVLJQHGXVLQJ&RPSXWDWLRQDO)OXLG

'\QDPLFV&)' DVD WRRO WRGHWHUPLQH WKH RZ SDWWHUQ

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GLVWULEXWLRQ7KHRZLVDFFHOHUDWHGDIWHUWKHEODGHZLWKWKH

momentum of the rotating velocity at the rotor side.

The high velocity region at the trailing edge of the fan

blade has been cushioned out with the guide vane and,

TOTAL

$118$/(/(&75,&$/

&26750

(T


19/48

FEATURE

June 2013 JJUURRUUTTEERRAA||1

17

7

WKXVWKHVWUHDPOLQLQJRIWKHRZLQWKHGLUHFWLRQRIRZLVGRQHZLWKUHGXFLQJ

swirling. As the guide vane is of a proprietary design, details of it cannot be

published.

7KH H[SHULPHQWDO DQDO\VLV ZDV FDUULHG RXW LQ DFFRUGDQFH WR $0&$

WHVWLQJ SURFHGXUH 7KH WRWDO HIFLHQF\ IRU WKH DGMXVWDEOH JXLGH YDQH

application had increased by 8% as compared to the axial fan without the

JXLGHYDQH5HIHUULQJWRWKH$0&$VWDQGDUGWKHUHODWLRQVKLSEHWZHHQ

SRZHU+DQGWKHWRWDOIDQHIFLHQF\LV

Where, is total pressure, Q LV WKH DLU RZ UDWH DQG

LVWKHFRPSUHVVLELOLW\FRHIFLHQW

)URPWKDWUHODWLRQVKLSWKHSRZHULVSURSRUWLRQDOWR WKHWRWDOHIFLHQF\

7KHUHIRUH ZKHQ WKH WRWDOHIFLHQF\ LQFUHDVHV E\ WKH IDQ SRZHUZLOO

decrease by 8%. The assumption of an 8% reduction in the power consumed

LVSUHVHQWHGLQ7DEOH7ZREDVHPHQWVZHUHFRQVLGHUHGIRUWKHRIFHWRZHU

7KHUHVXOWLVVKRZQLQ7DEOHDQGLQGLFDWHVWKDWVDYLQJVRI50

per year can be accrued if adjustable guide vanes are installed for thesupply/ exhaust fans.

In summary, the operating cost of large fans is often high enough to

MXVWLI\LPSURYLQJWKHIDQV\VWHPHIFLHQF\ZKLFKFDQRIIHUDTXLFNSD\EDFN

7KXV WKH DSSOLFDWLRQ RI &RPSXWDWLRQDO )OXLG '\QDPLFV &)' DOORZV D

system to be optimised at a much lower cost than the traditional cut and

dry method.n

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PHDVXUHPHQWRID[LDOIDQSHUIRUPDQFHVDQGYDOLGDWLRQZLWK&RPSXWDWLRQDO)OXLG'\QDPLFV


20/48


21/48

Geotechnics with geosynthetics

Huls Engineering Sdn. Bhd. (538064-A)Lot 56, Jalan PBS 14/3 Taman Perindustrian Bukit Serdang43300 Seri Kembangan Selangor Darul Ehsan MALAYSIA

Tel : +603 8941 9011 Fax : +603 8941 [email protected] www.hulsmalaysia.com

NAUE Asia Sdn. BhdNo. 18-M, Jalan SR 1/9 Seksyen 9 Serdang Raya43300 Seri Kembangan Selangor MalaysiaTel : +603 8945 2927 Fax : +603 8948 9927

[email protected] www.naue.com


22/48

FEATURE


equipment engineering community. It is worth to note that

proper application of this law could provide a scenario

allowing the pump to operate closer or at its BEP, providing

PRUHHIFLHQWRSHUDWLRQDQGLQWXUQFRVWVDYLQJV+RZHYHU

LW LV RXWOLQHG ZLWKRXW JRLQJ LQGHSWK LQWR WKH GHQLWLRQ RI

Eulers rotor dynamics equation (interested readers are

directed to (2); (3)).

The problem was tackled by references to multipleliterature and analysis of vendor pump curves to validate

OLWHUDWXUH FODLPV DORQJ ZLWK HOG H[SHULHQFH E\ LQGXVWULDO

H[SHUWV

The discussion would also be limited to the following

conditions, viz.:

Pump has no entrained solid or gas (2).

Scope does not include application to hydromagnetic

pumps (2).

Information presented generally cover medium range

VSHFLFVSHHGSXPSV

Simultaneous variation of diameter and rotational speed

at once is not included in the scope of this article andnot recommended (4).

9LVFRVLW\DQGXLGYDSRUL]DWLRQDUHQHJOLJLEOH(2).

3.0 BACKGROUND

3.1 Velocity Triangles

$IQLW\ /DZV IRU KHDG UHOLHV RQ (XOHUV URWRU G\QDPLFV

equation (Equation 1) which is derived from velocity

triangles. Noticeable from these triangles as depicted in

Figure 1(a) is that as periphery speed, U (also known as tip

VSHHGYDULHVWKHDEVROXWHXLGH[LWYHORFLW\9IROORZVVXLW

linearly. The same observation is noticed for variation in the

UHODWLYHXLGH[LWYHORFLW\:1, as illustrated in Figure 1(b).

:KHUH

$IQLW\/DZV,QWHUSUHWDWLRQVDQG$SSOLFDWLRQVIRU&HQWULIXJDO3XPSV

by Mr. Kelvin Mohan Thambiduray

1.0 ABSTRACT

2SHUDWLRQ RI URWDWLQJ HTXLSPHQW DW LWV EHVW HIFLHQF\

point (BEP) or close to it is every operators objective as

this leads to less wastage, higher cost savings, less wear

LQWKH PDFKLQH DQG D EXQGOH RIRWKHU EHQHWV+RZHYHU

in common practice, most process data acquired during

front-end engineering design (FEED) or conceptual

study phases do not accurately tally with actual process

conditions during actual plant startup. This of course is

due to many uncontrollable or unpredictable conditions

and as a result, in most cases, pumps do not operate at

rated points. A correction method should be implemented

to correct this deviation or to vary pump performance

based on process conditions that change over time,

permitting peak performance throughout the pumps life

F\FOH 2QHVXFK PHWKRG SUHVHQWHGKHUH LV$IQLW\/DZV

where performance improvements are achieved by toggling

with the impeller diameter or rotational speed. This article

SUHVHQWVDGHWDLOHGLQWHUSUHWDWLRQRI$IQLW\/DZVDQGWKHLU

usage for centrifugal pumps, alongside correction methodsto mitigate the large inaccuracies that have overshadowed

WKHZLGHVSUHDGXVDJHRI$IQLW\/DZV7KHVHPHWKRGVKDYH

been evaluated with vendor pump curves with the results

presented and discussed.

,1752'8&7,21

$IQLW\/DZVDOVRNQRZQDV)DQ/DZVGHULYHWKHLUQDPH

from their initial usage to re-rate fans. These laws have

proven successful in their application for fans generally

LQ LQGXVWULDO SODQWV ZKHUH WKH XLG PHGLXP EHLQJ GHDOW

with was air (light gas) with a relatively low head rise

and volume ratios that are commonly negligible. Theirapplications in other rotating equipment soon became

apparent, as centrifugal pumps and compressors are

both ideally governed by similar velocity triangles as fans.

$IQLW\/DZVIRUSXPSVKDYHRIWHQEHHQGHVFULEHGLQWHUPV

RIGLPHQVLRQOHVVQXPEHUVXVHGWRSUHGLFWRZKHDGDQG

power changes with diameter or speed variation under

VLPLODUDHURG\QDPLFRZDQGJHRPHWULFDOFRQGLWLRQVZLWK

a caveat that errors can be in the order of 20% (1).

The objective of this article is to bring awareness and put

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/DZV IRU DSSOLFDWLRQ LQ UHUDWLQJ SXPSV ZKHWKHU GXH WR

FKDQJHVLQSURFHVVUHTXLUHPHQWVRYHUWLPHRUXQH[SHFWHG

RZ FRQGLWLRQV DW FRPPLVVLRQLQJ 7KLV DUWLFOH GLVFXVVHV

methods generally overlooked by the general rotating

Figure 1: Velocity triangles (a) variation in periphery speed (b) variation

UHODWLYHXLGH[LWYHORFLW\

Equation 1

+6SHFLF+HDGN-NJ&u0HULGLRQDOYHORFLW\PV

83HULSKHU\YHORFLW\PV


23/48

FEATURE


$IQLW\/DZV

$IQLW\ /DZV DUH GHULYHG IURP WKH EDVLV WKDW KHDG

DQG RZUDWH DUHERWK GHSHQGHQWRQ YHORFLW\ WULDQJOHV

for geometrically similar impellers, and under ideal

conditions (as presented in Figure 1), they react linearly

to change either individually or simultaneously.

)OXLGRZUDWHGHQHGE\JHQHUDOWH[WERRNVVXJJHVW

the following:

+RZHYHUHPSLULFDOGDWDVKRZVWKDWRZUDWHWREH

directly proportional to diameter and speed change. The

following was proposed by A.J. Stepanoff and suggest (5)

LWVYDOLGLW\IRUDFRQVLGHUDEOHUDQJHRIVSHFLFVSHHGV2 .

:KHUH

+HDGEHLQJDIXQFWLRQRIWZRYHORFLWLHVDVLQGLFDWHG

in Equation 1 with velocity being a product of rotational

speed and impeller diameter as indicated in Equation 2a

then suggest;

3RZHU3EHLQJGHQHGDVDSURGXFWRIRZDQGKHDG

is then represented by referring to Equations 2c and 3b;

Equations 2c, 3b and 4b all represent the general

$IQLW\/DZVDSSOLFDEOHIRUSXPSV3. It should be noted

WKDW RWKHU IRUPV RI WKHVH ODZV H[LVW E\ HLWKHU KROGLQJ

one of the variables on the right side of these equations

constant or implementing correction constants, whichwould be elaborated further in Section 4 of this article.

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Equation 2a

Equation 2b

Equation 2c

Q)ORZ5DWHNJV$,PSHOOHUH[LWDUHDP2

N = Rotational Speed, rpm D = Impeller diameter, m

r = Impeller radius, m

Equation 3a

Equation 4a

Equation 3b

Equation 4b


24/48

FEATURE


(9$/8$7,212))$1/$:6

4.1 Effect of Scaling / Similitude

,QRUGHUWRDFFXUDWHO\DSSO\$IQLW\/DZV*XOOLFKVXJJHVWHG

that geometrical and dynamic similarity be maintained; to

EHPRUHVSHFLFDOOZHWWHGSDUWVDUHVHDOHGLQWKHVDPH

ratio whilst ensuring constant Euler, Froude and Reynolds

number (6). The effects of Froude4 and Reynolds5 number

for pumps are however, generally negligible unless detailed

loss investigation is required. Jacques and Florjancic

both added to these recommendations by implying that

$IQLW\ /DZV FDQ EH DSSOLHG DFFXUDWHO\ E\ PDLQWDLQLQJ

SXPSV HIFLHQF\ VSHFLF DQG VXFWLRQ VSHFLF VSHHG (4),(3). Jacques further suggested that only the same impeller

and not one geometrically similar be used for scaling as

manufacturing variation on wetted parts surface properties

ZLOO DIIHFW WKH DFFXUDF\ RI$IQLW\ /DZV(4)

(refer Section4.1.1 for further information).

%\SDUDSKUDVHFRQVHUYDWLRQRIXLGLPSHOOHUH[LWDQJOH

EHIRUHDQG DIWHUPRGLFDWLRQVZRXOGHQVXUHWKHDFFXUDF\

RI$IQLW\/DZV 7KHUHTXLUHPHQWV RXWOLQHG DUHWR HQVXUH

WKDW RZ NLQHPDWLFV DUH PDLQWDLQHG ZKLFK SUHYHQWV

variation in slip. As illustrated beforehand in Section

3.2, observation suggests that variation in impeller outer

diameter and rotational speed are major factors which

govern corresponding change in the pumps performance.

The following sub-sections will elaborate the effect of

variation in these parameters on pump performance.

4.1.1 Impeller Diameter VariationIt is common practice with most pump vendors to

construct impellers to be slightly larger than theoretically

FRPSXWHG DV UDWHG RZ ZLWKLQ RI %(3 LV

generally acceptable (7). If required pump performance

PRGLFDWLRQV DUH FDUULHG RXW E\ WULPPLQJ WKH LPSHOOHU

RU WKURWWOLQJ WKH RZ 7KLV SUDFWLFH SURYLGHV D EXIIHU IRU

the minor effects neglected during detailed engineering

calculations and also safeguard against under tolerance

LQ FRQWUDFWXDO WHUPV 'HYHORSLQJ DQ LPSHOOHU WR LWV H[DFW

theoretical calculated size might prove to be detrimental

FRPPHUFLDOO\ DQG WR WKH GHOLYHU\ VFKHGXOH LI WKH RZ

properties end up not meeting process requirements andremanufacturing is required.

+RZHYHURQHVKRXOGWDNHQRWHWKDWWKURWWOLQJWKHRZ

would mean the pump is over-sized, leading to detrimental

effects, and to name a few:

+LJKHUPDQXIDFWXULQJDQGRSHUDWLRQFRVW

+LJKHU HQHUJ\ FRQVXPSWLRQ DV WKH SXPS ZRXOG EH

UXQQLQJRQSDUWORDGGXHWRUHGXFHGSXPSHIFLHQF\

+LJKHU PDLQWHQDQFH FRVW DQG IUHTXHQF\ GXH WR

premature wear)

Possibility of pulsation (if inducers or suction impellers

DUHXVHGWRUHGXFHWKHKLJKHU136+URIDODUJHUSXPS

+LJKHUSRVVLELOLW\RIVHDOIDLOXUH

+LJKHU YLEUDWLRQV DQG QRLVH OHYHOV GXH WR SDUW ORDG

operation) (3).

Reducing impeller diameter on the other hand does

QRW VLJQLFDQWO\ FRVW DQ\ RI WKH EHIRUH PHQWLRQHG VLGH

effects besides the higher capital cost; if performed

properly and within the allowable range. Most literatures

would suggest the upper limit of the allowable range to

EH RI PD[LPXP GLDPHWHU ZKHUHDV VRPHSURSRVH LW

WREHXSWRRIPD[LPXPLPSHOOHUGLDPHWHU+RZHYHU

LQSUDFWLFHLWLVRIWHQWULPPHGWRDERXW6 only of

PD[LPXP LPSHOOHU GLDPHWHU )XUWKHU LPSHOOHU WULPEH\RQG

WKH DOORZDEOH UDQJH PLJKW FDXVH FRQVLGHUDEOH HIFLHQF\

drop and unstable pump performance due to increase in

HQHUJ\ORVVWRWXUEXOHQWRZ,QDGGLWLRQLIWKHLPSHOOHUWR

FDVLQJUDWLRH[FHHGVWKHSXPSGHVLJQOLPLWDQH[FHVVLYH

LQFUHPHQWRI VSHFLF YDQHORDGLQJZRXOG RFFXU UHVXOWLQJ

LQUHFLUFXODWLRQRZGLVWULEXWLRQSDWWHUQDFURVVWKHLPSHOOHU

H[LWWREHFRPHKLJKO\XQVWDEOHLQFUHDVLQJWKHWHQGHQF\RI

EDFNRZLQWKHSXPSHVSHFLDOO\LQKLJKHQHUJ\DQGGRXEOHVXFWLRQRZSXPSV(1).

$OVR$IQLW\/DZVFDQEHHDVLO\DSSOLHGWRHVWLPDWHWKH

DPRXQWRIWULPUHTXLUHGIRUDGHVLUHGRZSURSHUW\ZLWKD

FDYHDWWKDWWKHUHVXOWVE\XVLQJWKLV/DZGRHVQRWDFFXUDWHO\

UHHFW DFWXDO SK\VLFDO GDWD 5HDVRQV IRU WKLV RFFXUUHQFH

are breached to the geometrical similitude, before and after

the impeller trim. Factors which contribute to this include

failure of geometrical impeller trim to vary proportionally

with:

Impeller surface roughness (commonly negligible with

WKHH[FHSWLRQWRDSSOLFDWLRQRI$IQLW\/DZLQKLJKKHDG

RURZRSHUDWLRQV Impeller width and internal leakage clearances

Impeller to casing ratio

These mentioned factors cause increase in slip, which

HYLGHQWO\ FKDQJHV WKH DQJOHRI UHODWLYH XLG H[LW YHORFLW\

Due to this, impeller diameters are often trimmed in

SKDVHVRIVPDOOLQFUHPHQWVDQGUHWHVWHGXQWLOGHVLUHGRZ

conditions are achieved. Each time the impeller is trimmed

it would require to be re-balanced which could results in

FRVWO\PRGLFDWLRQV

A silver lining to the setbacks introduced by the usage of

$IQLW\/DZVZDVSURSRVHGE\%ORFKDQG%XGULVDVLOOXVWUDWHG

by Figure 2; a correction chart for impeller diameter trim

to compensate for hydraulic mismatches and mechanical

imperfections ;(9). Validity of this chart has been tested with

two separate pump vendor performance curves and initial

observation shows that improvement of accuracy ranging

EHWZHHQWRDSSUR[LPDWHO\0RUHLPSRUWDQWO\XVDJH

of the correction factor as indicated in Figure 3 and Figure 4

prevents impeller over cut, which is not correctable unless

by change of impeller or variation of rotational speed. The

question that lies here is what if the driver is not variable

speed, which is the common case in most scenarios where

impeller trimming is practiced. Do note however, even with

WKHXVDJHRIWKHFRUUHFWLRQIDFWRUWKHH[DFWUHTXLUHGWULPLV

not indicated with negligible effects, this is especially thecase when referring to Figure 3. This is highly likely owed

WRWKHKLJKRZRIWKLVSXPSLQZKLFKWKHXVDJHRIWKHVH

laws is highly not recommended as addressed later. Note


25/48


26/48

FEATURE


',D>

^^

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d

>:^d^^

Dd

dW

KRZHYHU WKH PHUH GHYLDWLRQ IRU DQ DSSUR[LPDWHO\PD[LPXP LPSHOOHU GLDPHWHU WULPIRU SXPSYHQGRU %

as demonstrated on Figure 4, which is likely owed to its

PRGHUDWH RZ DQG KHDG PHGLXP UDQJH VSHFLF VSHHG

Other methods that may also be applied to make impeller

trimming more favourable is trimming of vanes in an oblique

cut instead of the entire shroud (for closed impeller designs).

This reduces the effect of balancing issues and provides a

PRUHXQLIRUPH[LWRZDWWKHLPSHOOHUH[LW+RZHYHUFDUH

also should be taken when performing this to ensure that

shroud mechanical strength is not compromised.

,W LV VDIH WR SHUIRUP LQWHUSRODWLRQ RI DFWXDO RZ GDWD

being utilised (vendor to test and validate impeller with

VLPLODUVSHFLFVSHHGDWYDU\LQJVL]HVDQGH[WUDSRODWLRQ

under any circumstances avoided. If a new impeller is

WR EH SXUFKDVHG WR LQFUHDVH KHDG RU RZ FRQGLWLRQV D

complete hydraulic analysis is recommended. The failure

RIWKHFRUUHFWLRQIDFWRUZKHQH[WUDSRODWHGLVLQGLFDWHGRQ

Figure 3, showing an undersized impeller, which would

ultimately lead to dissatisfactory pump performance. Pump

XQGHUSHUIRUPDQFH RURYHUVL]LQJ LVWR EHH[SHFWHG LIWKH

Figure 2: Impeller trim correction [Image adopted from (9); (8)].

Figure 3: Comparison with and without correction factor proposed on

JHQHUDOYHQGRU$SXPSFXUYH6,6SHFLF6SHHG


27/48

FEATURE


SURFHVVFRQGLWLRQVDUHH[WUDSRODWHGEH\RQGDFHUWDLQRZWKUHVKROG

$QRWKHU LPSRUWDQW OLPLWDWLRQ WR FRQVLGHU LV WKH DSSOLFDEOH VSHFLF

VSHHGUDQJH ZKLFK $IQLW\ /DZVJRYHUQ 3XPSV ZLWKORZ VSHFLF VSHHG

are designed to maintain the impeller clearance width for a considerable

distance away from the outer diameter; this disrupts the width to diameter

ratio which maintains a near constant change as seen in middle range

VSHFLFVSHHGSXPSV+LJKVSHFLFVSHHGSXPSVRQWKHRWKHUKDQGKDYH

YHU\VKRUWEODGHV+HQFHWKH\DUHYHU\VHQVLWLYHWRGLDPHWHUFKDQJH (5) due

to possibility of inadequate vane overlap causing hydraulic problems to

arise(9)&RQVHTXHQWO\ERWKWKHVHVSHFLFVSHHGUDQJHVGRQRWFRUUHVSRQG

ZHOOZLWK$IQLW\/DZV0HQWLRQHGLQ6HFWLRQWKDW$IQLW\/DZVUHO\RQ

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highly unreliable in these cases(4).

4.1.2 Impeller Rotational Speed Variation

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process conditions is by changing the impeller rotational speed with variablespeed drive system (VSD). Use of VSDs with electric motor drive include

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steam turbine, gas turbine, reciprocating engine or even hydraulic power

recovery turbine. Note all of these VSD systems have different limitations on

allowable speed range which must be taken into account.

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too. For one, the larger number of equipment required directly increases

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roughness not varying proportionally with speed change. Nevertheless,

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scenarios(3)$OVRDVDGGUHVVHGLQ6HFWLRQIRU$IQLW\/DZVWREHXVHG

Figure 4: Comparison with and without correction factor proposed on general vendor B pump

FXUYH6,6SHFLF6SHHG

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28/48

FEATURE


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however is not seen in practice, being supported from a large

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variables, one of which is rotational speed(2). Though for

small speed changes the effects that cause inaccuracy to

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Figure 5. A pump manufacturer had introduced a method

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after speed variation

(10)

.

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applied to vary rotational speed, one should be cautious and

take mechanical limitations of the pump into consideration,

as increasing the rotational speed without a proper rotor

dynamic study may cause the shaft to operate dangerously

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vibration, with pump part failures following suit. Increasing

the shaft size to counter this effect can be considered with a

detailed engineering study, as the shaft size directly affects

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of the pump in operation is very small, as common pump

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is increased(11).

&21&/86,21

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to the common fallacy of low accuracy predictions and

unreliability. This is compounded with competition frompresent day high speed computational hardware and

advancing CFD software with the capability to accurately

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impeller diameter. These factors are main causes as to why

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this article brings to light the possibility of these laws being

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tolerable accuracy during feasibility stage or even during

trouble-shooting, if applied with proper care and the methods

outlined. Although further thorough research is strongly

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practice. Future works to be considered should include

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caution should always be taken especially when trimming

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properties.

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30/48

FEATURE


Product Development ThroughThe Use Of Rapid Prototyping

by Ir. Dr Tan Chee Fai

THE competition and rapid development of the world

market is causing the industry to produce more quality

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industry needs to plan and adopt the right strategy in order

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Lean Manufacturing and Concurrent Engineering are

used. To reduce the production time and minimise designHUURU HQJLQHHUVQHHG WR FUHDWH WKHUDSLG PRGHOV LQ HDFK

development stage.

Rapid prototyping (RP) technology is a means through

which the product geometry as modelled in the earlier

stages can be directly utilised to obtain the physical shape

of a component. This helps explore and prevent the design

problems during the manufacturing stage. Rapid prototyping

allows real models and tools to be produced directly from

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useful in the early stage of product development as well as

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The rapid prototyping industry is experiencing

impressive growth although it was badly hit by the global

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only a few processes are widely accepted by the industry.

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system and Envision Tec Perfactory are some of the widely

used systems. Yet most of the present systems have not

completely addressed the industrys needs. MachinesKDYH OLPLWDWLRQV LQ WKHLU SHUIRUPDQFHV DQG GLPHQVLRQDO

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MAJOR RP APPLICATIONS IN INDUSTRY

Offshore and Abyssal Engineering

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research. The outcome from the research found that RP

has improved and replaced the conventional methodsto develop new types of products and procedures. RP

therefore has great potential in offshore engineering.

Engineering

The aerospace industry in the United State uses RP

technology to manufacture the customized parts for the

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RP also plays an important role in the automotive

industry. RP models are used for design studies (aestheticevaluation) and physical experimentation (aerodynamic

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Architecture

The Rapid Prototyping Group from University of Strathclyde

of the United Kingdom has applied RP in the architectural

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of architectural models can be described using seven

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Medical Applications

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conscious adults can have their teeth straightened without

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also be applied in the hearing aids industry to produceFXVWRPLVHG KHDULQJ DLG VKHOOV IRU SDWLHQWV ,Q DGGLWLRQ

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the patients face which helps to reduce the formation of

scarred tissue.

Arts and Archaeology

RP is being used in the restoration of artefacts. RP can

duplicate ancient statues and ornaments which had

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damage can then be corrected using the software. In this

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Sciences

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31/48

FEATURE


chains upscale for teaching and learning purposes in the

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various projects or as a product development tool for small

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WKH RQO\ GUDZEDFN LV WKDW RI WKH TXDOLW\ RI WKH QLVKHG

product will not be as good due to the low resolution of

the machine.

REFERENCES

[1] Wiedemann, B. and Jantzen, H-A., Strategies and applications

for rapid product and process development in Daimler-Benz AG,

Computers in Industry, 39, 1999 pp. 11-25.

[2] Emerald Group Publishing Limited, Innovations: State of the rapid

prototyping industry, Strategic Direction, 20, 2004 pp. 27-29.

[3] Egodawatta, A.K.m Harrison, D.K., A.K.M. De Silva and G. Haritos,

A new rapid prototyping/tooling based on layered manufacturing

technology, Proceeding of Third International Conference on

Advanced Manufacturing Technology, Kuala Lumpur, 11-13 May

2004, pp. 401-405.

[4] Wieneke, B. M. T. and Gerber, H.W., Rapid prototyping technology

new potentials for offshore and abyssal engineering, Proceedings

of the Thirteenth International Offshore and Polar Engineering

Conference, Honolulu, 25-29 May 2003 pp. 27.

[5] Ryder, G., Ion, B., Green, G., Harrison, D. and Wood, B., Rapid

design and manufacture tools in architecture, Automation in

Construction 11, 2002 pp. 279 290.

[6] Burry, M. Rapid prototyping, CAD/CAM and human factors,

Automation in Construction, 11, 2002 pp. 313-333.

[7] http://www.wohlesassociates.com/EuroMold-2001-paper.html(accessed on 18/5/2004)

Ir. Dr Tan Chee Fai is a committee member of the Mechanical Engineering

Technical Division and a Senior Lecturer, Integrated Design Research Group

(IDeA), Faculty of Mechanical Engineering, Universiti Teknikal Malaysia

Melaka.

Fill in the remaining 80 squares with single digits 1-9 such that there is no repeat of the digit in every Row,

Column and Block of nine squares. The number at the top left hand corner of the dotted cage indicates the total

for the digits that the cage encompasses.

For tips on solving, visit www.1sudoku.com.my

Twin Tree Publishing

(Solution is on page 44 of this issue.)

1SUDOKUCenterpiece "1"Develop both sides of the brain with 1Sudokuby Mr. Lim Teck Guan

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32/48

ENGINEERING DIGEST


Civil Engineering Dominates Q1Construction Activity

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33/48

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34/48


35/48

FORUM


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THE Institution of Engineers, Malaysia (IEM) has won a bid

to become the organiser of the 7th International Conference

on Cooling & Heating Technologies in 2014 (ICCHT-2014),

which will be held in Malaysia. IEM was invited by American

Society of Heating, Refrigerating and Air-conditioning

Engineers (ASHRAE) Singapore Chapter to participate and

bid for the ICCHT-2014. Mechanical Engineering Technical

Division (METD) was given the task by IEM to be in chargeof the bidding of ICCHT-2014. After several preparatory

meetings, METD had decided to send a delegation to bid

for the organisation of 7th ICCHT during the 6th ICCHT in

Xian, China, between 9 and 12 November 2012.

The proposal from METD was supported by IEM and

for the ICCHT-2014, METD has decided to work with IEM

Training Centre (IEM-TC). After some preparations and

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Xian, China, to meet the ICCHT main committee and to

present the proposal. The delegation team was represented

by Ir. Noor Hisham Yahaya (Team Leader), Ir. Fam Yew Hin,

Ir. Luk Chau Beng, Ir. Gopal Narian Kutty, Ir. Yim Hong

Wa (representative from IEM-TC), and Ir. Dr Tan Chee

Fai. There were two intensive discussion sessions and a

presentation during the 6th International Conference on

Cooling & Heating Technologies (ICCHT-2012). Finally, the

main ICCHT committee approved METDs proposal and

awarded the organising right of 7th ICCHT to the Institution

of Engineers, Malaysia.

The ICCHT was formed by a group of researchers

from four countries, namely Professor Maogang He (Xian

Jiatong University, China), Professor Aryandi Suwono

(Institut Teknologi Bandung, Indonesia), Professor Hanshik

Chung (Gyeingsang National University, Korea), Professor

Shengqiang Shen (Dalian University of Technology, China),and Professor S.H. Winoto (National University of Singapore,

Singapore). Their main research interest are cooling and

heating technologies such as HVAC system, heat transfer,

renewable energy and refrigeration engineering.

The 1st International Conference on Cooling & Heating

Technologies was held in Hanoi Vietnam (January 2005,

whereas the subsequent conferences were held in Dalian,

China (July 2006); Tokyo, Japan (July 2007); Jinhae,

Korea (October 2008) and Bandung, Indonesia (December

2010). The previous ICCHTs had gathered more than 100

cooling and heating researchers from different countries

such as China, Japan, Korea, Singapore and Indonesia.The 7th International Conference on Cooling & Heating

Technologies will be organised in Kuala Lumpur from 4

November to 6 November 2014.

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36/48

JACKED ANCHORS(Patent No: MY113979A)

Advantages: -

t Assured Capacitiest Improvement To Soil Properties

t No Collapsed Drilled Holes &Sink-Holes

t Much Shorter Construction Time

t Lower Construction Cost

t No Muddy Working Conditions

t Fully Mechanised Process

The Geotechnical Specialist Since 1986

Solutions To Your Geotechnical Needs / Problems Using: -

STONED COLUMNS(Patent No: MY128328A)

Excellent For Soft Ground

Engineering

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wide recognition and has establisheditself to be the leading, the mostactive and reputable SpecialistContractor in this particular field ofGeotechnical Engineering. SGEbuilds its strength and reputation, allupon its clients confidence.

Electrified Double Track Project More Than 70 Locations, 9m

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SGEs Fleet of Stone Column Machinery

Advantages: -

t 100% Dry Operation-No Environmental Contamination

t Every Stone Column is TestedDuring Construction to 2 TimesWorking Capacity

t Volumetric Proof of Design Diameter

t 100% Displacement Method

t No Problem on Human ErrorProcess is Fully Mechanised

t Strong Technical Backing ByReputable Institutions For a LocalInnovative System

Double Track Project at Gemencheh, Negeri Sembilan

17m CBP Retaining Wall Putrajaya

(January 2010 IEM Front Cover Caption) Stone Column for New Pantai ExpresswayMalaysian Invention Vs European System (Far End)

Pahang Selangor Raw Water Transfer Tunnel, Karak

SGE Jacked Anchors for 10-12m CBP Retaining Wall,SMART Tunnel.

East Coast Expressway, Kerteh, TerengganuClose to 100000m of Stone Column was constructed A Stabilized 60m Cut Slope For Pos Betau, Cameron

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Our Services Include: Problem Appraisal, Proposal, Construction, Monitoring

Geotechnic Sdn Bhd

For Enquiries Please Contact: 019-3824875 (Aw), 019-3822688 (Su), 0193101760 (Yu), 03-772999826


37/48

FORUM


35

5

RReettrreeaattaannddBBrraaiinnssttoorrmmiinnggWWoorrkksshhoopp

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THE annual Retreat and Brainstorming Workshop of

the Mechanical Engineering Technical Division (METD)

for Session 2012/13 was held on 15 December 2012 at

Jurutera June 2013

Documents

Transcript of Jurutera June 2013