Lukman Alhakim_MEng_Project Portfolio_Aug 2015
-
Upload
lukman-alhakim-wahid -
Category
Documents
-
view
24 -
download
1
Transcript of Lukman Alhakim_MEng_Project Portfolio_Aug 2015
PROJECT
PORTFOLIO
MEng, Mechanical
Engineering (Hons)
Lukman Alhakim Ab Wahid
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 1 of 35
Table of Contents
Project Engineering ..............................................................................................................2 - 12
1. Automatic Lashing Platform (ALP) ......................................................................................... 2
2. Mitsubishi Heavy Industry (MHI) – Stacking Guide .............................................................. 10
3. Evaluation & Qualification of a New Vendor with Hydraulic Scope of Supply ......................... 11
Mechanical Test .................................................................................................................. 13 - 31
1. Evaluation of New Flipper Design for Rotterdam World Gateway Spreader ............................. 16
2. Provision of Corrosion Evaluation for Rotterdam World Gateway
(RWG) Spreader – Post Commissioning................................................................................. 17
3. Evaluation of Photovoltaic Sensors Under Harsh Environmental
Conditions – ALP Component Testing ................................................................................... 18
4. Provision of Design & Fabrication of RWG Mechanical Test Jig
& Conceptual Verification of Spreader Unit ........................................................................... 20
5. Corrosion Evaluation of Metric Precision Steel Pipes
for Vendor Comparative Assessment ..................................................................................... 21
6. Evaluation of Anti-Rust Compound for Product
Comparative Assessment – Dinitrol & Techtyl ....................................................................... 23
7. Evaluation of Oil Level & Temperature Indicator for Vendor
Comparative Assessment – IFM & Hemomatik ...................................................................... 24
8. Evaluation of Oil Heater for Vendor Comparative Assessment EVT & AVAK ........................ 25
9. Evaluation of Hydraulic Hoses & Clamps for Suitable Pairing Selection .................................. 26
10. Performance Evaluation of Non-Metallic Dampers – A Comparative Assessment ..................... 27
11. Evaluation of Sheave Wheels for Vendor Comparative Assessment ......................................... 28
12. Provision of Functional Test for Guide Block & Twistlock Arm
for Vendor Comparative Assessment ..................................................................................... 29
13. Provision of Functional Test for Hydraulic Leakage Verification on Hose Assemblies .............. 30
14. Provision of Functional Test for Hydraulic Leakage Verification
on RWG Valves & Manifold Blocks ...................................................................................... 31
Marine Machinery Design - Spreaders............................................................................... 32 – 35
1. Local ................................................................................................................................... 34
2. International ......................................................................................................................... 34
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 2 of 35
Project Engineering
Apr 13 – Mar 15
“Bridges the boundaries between engineering and
project management”
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 3 of 35
Automatic Lashing Platform (ALP) Apr 13 - Mar 15 (24 months)
Project Description:
ALP (red machine on the ground) is the solution for automated handling of twistlocks1 within
shipping terminals. Located under the gantry cranes this device increases operational efficiency by
reducing the load/unload cycle time & promotes safety by eliminating human labour.
It is self-sufficient via means of converting potential energy from the weight of containers into
pressurised hydraulic & pneumatic power. Stored within linear actuators & accumulators the energy
will then be gradually released to serve its fundamental & auxiliary functions.
Engineering
Standard
Skill Segment
EN 15056, ISO 2553, ISO 13920, ISO 2768, ISO 1302, EN 13849-1,
EN 13681, EN 1005, EN 547-2, EN 547-3, , ISO 17165-2, 2006/42/EC,
1997/23/EC, ASME B16.5 & ASME B31.3 & NACE
Project Planning, Sheet Metal, Welding, Hydraulic System, Hydraulic
Fluid Power, Ergonomics, Process Piping, European Directives (CE),
Corrosion Study, AutoCAD 2D2, Autodesk Inventor 3D
3, Jig Design,
Testing, Technical Report, & Vendor Management
Challenges Language barrier & work-flow culture
Lesson Learnt Fluidity of information between testing & design team will propel
progress & boost productivity
1 A twistlock and corner casting together form a standardised rotating connector for securing shipping containers 2 Generally utilized for hydraulic schematic & P&ID designs 3 Structural design & finite element analysis (FEA) of the overall machine as well as its critical sub-components (i.e. load bearing sections, pick – points segments). In addition the dynamic characteristic of non-metallic components such as rubber
dampers and hydraulic fluid actuators were being simulated via internal solver within Autodesk Inventor software
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 4 of 35
Scope of work:
1. Design
� Basic Engineering Design (BED)
Site Survey& Prototype Documentation
o Design data acquisition – The established prototype unit created in Böel, Germany
were being scrutinised for details of pipe routings, component allocation &
fundamental system understanding4
o Subsequent visits were utilized for design verification & endorsement of previous
engineering solutions as well as creating new design entry for impromptu fixes
o Each documentation period were segregated into three (3) different phases;
• Initial – Documentation of new technology implemented onto the existing
prototype unit
• Intermediate – Reflection of previous way forward, discussion on solution
costing & relevant alternative approach
• Final – Product development planning for future deliveries; mechanical &
hydraulic design. Components localization for procurement leverage
Fundamental Pipe Modelling
4 Only apply to the first site visit where product owner describe in detail of ALP’s fundamental working principal in detail in
the scope of mechanical, hydraulics, electrical & control system
1 2
Figure 1: 1 - Fundamental pipe routing, 2 – A pipe sub-drawing with dimensions
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 5 of 35
Fundamental Pipe Modelling (continued)
o Drafting of 3D pipe routing as outline for detail design stage were perfected in
multiple phases. Section of interest are trolley, bottom frame & upper frame
o Preliminary optimization in the scope of component reduction and introduction of
continual pipe routing which promotes higher flow efficiency
o Improvements updates on hydraulic P&ID that covers the energy, lifting, trolley &
manipulator system; in-sync with development planning
Conceptual Proposal
o Feasibility studies and engineering concepts were put into action to address ongoing
issues & future optimization in the scope of:
• Safety
Focusing on design of safety signs depicting potential hazardous
complication as well as implementation of physical counter measures e.g.
anti-slip floorings.
• Ergonomics
Design modification that advocate ergonomic considerations as stipulated in
ISO 13861, EN 614-1 & 2 as well as CEN guide 414. Personnel access
into/out from machine, lighting intensity & duration of working in abnormal
posture were some of the design examples with ergonomics due diligence.
• Certification
As European terminals will be amongst the prospectus clients to market this
machine, compliance to the European Directive is paramount. Fundamental
requirements as per stipulated in 97/23/EC & 2006/42/EC were implemented
especially in the scope of machinery process, safety & pressure equipment.
Figure 2 - Conceptual optimization sketches drawn during a site survey
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 6 of 35
• Cost Reduction
Selection & approval of engineering components with due diligence. This is
achieved via practicing accurate material & steel profile selection and other
purchase components; avoiding over specifications. Working hand in hand
with procurement in outsourcing components with premium price tag.
• Function Optimization
Improvements were segregated into multiple-phases; the initial stage tackles
fundamental issues via brainstorming conceptual ideas across multi-
disciplinary division. Locus of development is the energy system where
boosting the hydraulic efficiency is paramount in achieving a self-sufficient
setup.
� Detail Engineering (DE)
Engineering Drawings
Provision of preparing detail engineering drawings5 for in-house fabrication process &
production reference during assembly stage. The following are the type of drawings
produced for this project:
o Component drawings o Hydraulic Schematics
o General Assembly (GA) o Hydraulic P&ID
o Bill of Materials (BOM) o Pipe Assemblies
5 Compliance to EN 15056, ISO 2553, ISO 13920, ISO 2768, & ISO 1302
1
2
3
4
Figure 3: 1& 2 - Pipe assemblies modelling, 3 - Hydraulic P&ID, 4 – A sample of pipe drawing
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 7 of 35
Operation Manual
ALP operation manual was compiled in a continuous & chronological manner from detail
design & until testing phase. In the scope of mechanical & piping, information related to
hydraulic functionality, detail description of sub-system & components were allocated
into respective chapters. Supplementary visual aids were provided in the form of
commercialized perspective drawings.
2. Trainer
Conducted an introductory product data management (PDM)6 training for ALP technical team
in Böel, Germany on October 2013. Supplemental coaching was also provided on the
Autodesk Inventor 3D - the project primary designing tool.
6 Autodesk Vault 2013 was the PDM system utilized at that time
Figure 4 - Visual aids for manual compilation; samples depicting various greasing points
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 8 of 35
3. Testing
� In-house testing
The conceptual verification of new engineering designs was awarded to local engineering
team in Malaysia. Provision of test procedures, methodology and resource management
were brought up during technical meetings for multi-disciplinary discussion prior to
commencement of any test activities.
Scope of work includes:
o Project Planning – Time scheduling & resource management (human & capital)
o BED – Basic fixture design that able to deliver comparative results from actual
operating conditions. Working closely with sourcing, vendors & fabricators to
achieve fixture design that are reliable, cost efficient and specifications
compliance
o Execution – Initial setup, performing test and data acquisition
o Documentation – Technical report compilation with quantifiable end-results
leading to relevant recommendation on the tested system/components
2
1
Figure 5: 1 - Sensor evaluation setup, 2 - Assessment on manipulator lifting cylinder
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 9 of 35
� Field Test
Engaged in multiple field testing in Southampton & Hamburg shipping terminals.
Primary task involves hydraulic data acquisition, fault findings & documentation. These
discoveries will then be analysed and added into the active development list.
Achievements: ✔ Laid groundwork on the 3D piping layout for ALP production unit ✔ Achieved 15% (RM 195,000+) cost7 reduction from continuous collaborative effort
with sourcing team in the field of:
� Component harmonisation - Control valves & retaining clamps
� Localization of hydraulic pipes & auxiliary connectors
� Breaking down costly packages into individual components ✔ Post PDM training session, respective engineers were able to independently monitor
design updates remotely; boosting team productivity
Recommendations:
7 In reference to direct cost from mechanical components purchase i.e. pipes, hydraulic hoses, actuators and auxiliary valves
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 10 of 35
Provision of Detail Engineering of Hydraulic Schematics Feb – Mar 14 (1 month)
for Mitsubishi Heavy Industries (MHI) – Stacking Guide
Project Description:
Spearheaded hydraulic design integration between client’s hydraulic functions and the standard yard
spreader; enabling value adding features of side stacking & supplementary pump-failure prevention.
A time critical collaborative project with immense business potential for repeat orders.
Engineering Standard
Skill Segment
EN 15056, ISO 2553, ISO 13920, ISO 2768 & ISO 1302
Hydraulic System, AutoCAD 2D, Autodesk Inventor 3D
Challenges Client’s reference drawings released in stages
Lesson Learnt Communication ought to be made to end-user directly
without an intermediate entity (commercial personnel)
Scope of work:
1. BED & DE
� Conceptual and cross reference study based on client’s hydraulic P&ID
� Integration proposal according to production’s common components8
� Detail design which consist of general assembly (GA), hydraulic P&ID & preparation of
bill of material (BOM)
2. Procurement
� Outsourcing & localization of special valves for cost reduction purposes
Achievements:
The project was successfully offered to client two weeks prior to due date with an additional 13% cost
savings
8 Consisting of hydraulic control valves, connecting lines & instrumentation components
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 11 of 35
Evaluation & Qualification of a New Vendor with Hydraulic Scope of Supply (6 months)
Project Description:
Due to the new management policy9 an existing vendor for hydraulic services were to end their
contract of supply. The scope of evaluation for the new replacement shall cover the following
province:
1. Internal processes & system evaluation
2. Product features & product process assessment
Engineering
Standard
Skill Segment
DIN 3015, ISO 17165-1, ISO 6606, ISO 14993 &
ISO 10289
Vendor Qualification, Hydraulic Fluid Power, NDT
& Technical Report
Challenges A dynamic & thorough assessment program
9 A more stringent approach in dealing with underperforming vendors
Figure 6 - Supplier's warehouse & test facilities
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 12 of 35
Scope of work:
1. Site Visit
� To verify vendor’s facility is within satisfactory operational conditions
� Reviewing safety aspects of the facility & their provision for personnel protective
equipment (PPE)
� Assessment on measurement techniques, calibration programmes & testing schemes
� Reviewing internal document control & process flow
2. Testing
� Evaluation of component10
covering the following scope:
o Material specification – DIN 3015
o Labelling – ISO 17165-1
o Performance – ISO 6606, ISO 14993 & ISO 10289
o Dimensions – Physical dimension vs. technical drawings
3. Documentation
� Site visit evaluation report – An independent review
� Technical report to include rejection/approval of individual component tested
Outcome:
Approval of the new supplier with due diligence; ongoing monitoring & evaluation especially in the
realm of dimensional control (for DIN 3015 clamps) as well as hoses labelling (as per depicted in ISO
17165‐1 - Appendix 7.2)
10 Consisting of hydraulic hose assemblies, DIN 3015 rated clamps & auxiliary supplied loose connectors
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 13 of 35
Mechanical Testing
Jan 12 – Aug 13
“Determination of mechanical properties and
behaviour of material, structures and machines”
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 14 of 35
Figure 7 – Test Flow Chart
Project Segregation:
Projects were segregated by their requestor/owners as shown in diagram below:
Figure 8 – Chart Depicting Test Ownership
Achievements: ✔ PDM database administrator for Test Centre department - Mechanical jigs ✔ Rectified 520 errors in PDM system - Saved RM10k in IT consultancy fees ✔ Introduced & standardized technical report template for Test Department ✔ A department backbone - Lead to achieve 1/3 of its KPI for 2H FY 2012 ✔ Centralization of in house power-pack11
units – BED for budgetary approval ✔ Spearheaded design & material selection for Rotterdam World Gateway jig ✔ Entirely responsible for revising 2D jigs design into 3D CAD models
11 Hydraulic pump sets that can cater up to 250 bar of hydraulic fluid pressure
Test Owners
Sourcing, R&D, QA &
Engineering
Department
Feasibility Stdy.
Facilities
Budgetary,
Man power,
& Schedule
Testing
Planning,
BED, FEED,
Jig Fabrication
& Execution
Deliverables
Tech. Report with
Unprejudiced
Recommendation
Revise or 3rd party
Owners/
Requestor
R&D
(Sweden &
Germany)
Customer
Engineering
Sourcing
Department
Quality
Assurance
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 15 of 35
Recommendations:
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 16 of 35
Evaluation of New Flipper Design for Rotterdam World Gateway
Spreader (3 months)
Project Description:
Mechanical flippers are an essential part of a crane spreader. It provides guidance to align the
spreader’s twistlocks into container’s corner castings during pickup sequence. For this particular
project, a hybrid design was explored where the normal practice of vertical open/close motion were
replaced with a horizontal swing motion. Parameters related to the efficiency of this new design were
tested before commencing to mass production phase.
Engineering
Standard
Skill Segment
EN 15056, ISO 2553, ISO 13920, ISO 2768, ISO 1302, EN 1005, EN 547-2,
EN 547-3, ISO 4406, ISO 17165-2
Project Planning, Hydraulic System, Jig Design, Testing & Technical Report
Challenges Noble jig design & resource limitations
Scope of work:
1. BED
� Conceptual study &planning of Mechanical Test to allow the following parameters to be
evaluated:
o Locking motion fluidity – To achieve a seamless angular opening & closing by
understanding the relation between location of linear actuator with respect to the
flipper and its structural frame
o Hydraulic hose sizing – To control the swing speed of opening & closing within
the working time frame as dictated within internal standard. Alternative
introduction of reducing connectors to be explored to promote hose sizing
standardization – procurement leverage
o Impact assessment – Noise & vibration data analysis due metal to metal contact
during operation
2. Procurement Support
� Working closely with vendors and sourcing team to achieve test setup that are technically
verified, reliable & cost effective
3. Testing & Documentation
� Initial fixture setup & component assembly
� Data acquisition with the aid of noise & vibration logger
� Technical report to include approval/rejection of the new design
Outcome:
1. Introduction of reducing connectors for precise motion & speed control
2. Proposal to fine tuning the software algorithm to control the motion sequence - reducing
impact sound emission
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 17 of 35
Provision of Corrosion for Rotterdam World Gateway Spreader
- Post Commissioning (4 months)
Project Description:
A Quality Service Report (QSR) related to corrosion of RWG spreader occurring in Port of
Rotterdam, Netherland was issued by the in-charged service engineer. This has raised concerned from
top management since it was taken placed in one of the busiest terminal in Europe; global reputation
were as stake. Considering past spreaders were in good working condition with acceptable corrosion
allowance, this project shall investigate the root cause of such an abnormal circumstances.
Areas which were severely affected by corrosion:
1. Hydraulic linear actuator – piston unit
2. Retainer plate for load bearing shaft
3. Exposed components prone to regular use – e.g. ladder steps & walkways
Engineering
Standard
Skill Segment
ISO 9227, ISO 14993, ISO 2081, ISO 10289 & NACE
Project Planning, Corrosion Study, Testing & Technical Report
Challenges Reference were limited to photos taken by service personnel
Scope of work:
1. BED
� Conceptual study, planning & execution of Environmental Test to allow the following
parameters to be evaluated:
o Corrosion resistance – Evaluation of respective components under in-house salt
spray test in accordance with ISO 14993
o Mounting orientation & location – Comparative evaluation on corrosion rate
o External factors – Environmental acidity & abrasive wind borne particles
2. Testing & Documentation
� Physical & visual inspection of coating performance as per dictated in ISO 10289
� Technical report to recommend relevant counter measures to curb future rust initiation
Outcome:
1. Based on the spreader’s service condition12
a higher electroplated coating thickness were
suggested - from 12 to 25 micron
2. Introduction of anti-rust coating on unpainted steel structure surfaces & hydraulic connectors
3. Other components with low dimensional tolerance to be coated with hot dipped galvanization
12 Corresponding to outdoor service class in severe corrosive conditions e.g. marine or industrial (ISO 2081)
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 18 of 35
Evaluation of Photovoltaic Sensors Under Harsh Environmental
Conditions – ALP Component Testing (3 months)
Project Description:
One of the fundamental functions of the ALP machine is to be able to detect the presence/absence of
twistlock via special tool13
. A photovoltaic sensor is cardinal to accomplish this function. However
due to the exposed nature of a marine working condition14
, common issues such as intermittent loss of
sensor signal will need to be addressed for continuity of machinery operation.
The aim is to verify the presence of any of the following failure modes:
1. Signal loss – Under pre-defined conditions with variation in temperature, illumination state &
reflector surface conditions
2. Alignment w.r.t reflector - Due to sensor’s finite field of sensing
Engineering Standard
Skill Segment
EN 15056, ISO 2553, ISO 13920, ISO 2768 & ISO 1302
Sheet Metal, Testing, AutoCAD 2D, Autodesk Inventor 3D &
Technical Report
Challenges Simulation of harsh marine conditions within in-house test facility
13 A patented tool that serve the function of locking/unlocking of twistlock to & from container’s corner casting. It is
operated by means of rotary hydraulic actuators 14 Typical weathering conditions such as heavy rainfall, snowing & ice flakes. Other external contributing factors for
instance accumulation of dirt & oil from prolonged operation period.
1 2
3 4
Figure 9 : 1&2 - Test fixture to evaluate environmental conditions, 3 - Fixture for alignment assessment,
4 - The actual sensor used on the prototype unit
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 19 of 35
Scope of work:
1. BED
� Conceptual study, planning & execution of Mechanical Test to allow the following
parameters to be evaluated:
o Different weathering elements
o Sensor orientation & angular tilt of the sensor w.r.t its reflector (twistlock)
o Distance limitation w.r.t its reflector (twistlock)
o Fitness-for-purpose evaluation on the weather enclosure design
� Working closely with German team to achieve a test setup that is capable of reproducing
the actual operating conditions
2. Testing
� Initial fixture setup & component assembly
� Scheduled planning for test technician to run & exquisite relevant test data
3. Documentation
� Technical report to include approval/rejection of the tested sensor & its enclosure
Outcome:
1. Recommendation on sensor’s optimum operating range & angular tilt
2. Verification of the present weather protection enclosure – A cost effective solution with ease
of visual monitoring, maintenance access & impervious to majority of the tested elements
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 20 of 35
Provision of Design & Fabrication of RWG Mechanical Test Jig
& Conceptual Verification of Spreader Unit (4 months)
Project Description:
A new and anticipated spreader line equipped with angular tilting features were to be tested within
production facility. This project focuses on:
1. The design of its testing fixture
2. Conceptual verification test of the new angular tilting features
Engineering
Standard
Skill Segment
EN 15056, ISO 2553, ISO 13920, ISO 2768, ISO 1302, EN 1005, EN 547-
2, EN 547-3, ISO 4406, ISO 17165-2
Project planning, Sheet Metal, Welding, Hydraulic Fluid Power, FEA,
Autodesk Inventor 3D & Technical Report
Challenges Cost driven, time constraint & achieving precision a large steel structure
Scope of work:
1. BED & DE
� Project planning from basic engineering phase to delivery into production facility
� Raw materials & fabrication costing, resource allocation, logistics & assembly procedures
� Conceptual design of the test fixture in reference to test parameters & structural limitation
� Detail design which consist of general assembly (GA) & components drawings,
preparation of bill of material (BOM) for fabricators
2. Procurement & Vendor Management
� Localization of raw materials for cost reduction process – Refraining from profiled steel
� Proactively working with external fabricators to ensure design tolerance were achieved
3. Testing
� Planning & execution of Mechanical & Hydraulic Tests on the spreader unit
� Collaboration with QC Department for initial fixture setup, assembly & commissioning
� Data acquisition with Hydac HMG 3010 data logger – pressure, temperature & flow rate
4. Documentation
� Compilation of technical manual, safety operating procedures & maintenance15
scheme
� Technical report to include approval/rejection of individual features of the new spreader
Achievements: ✔ Received recognition from local QC & R&D Sweden post-test fixture commissioning due to its
low cost and on-time project delivery
15 Focusing on areas prone to abrasion where greasing procedures & intervals were proposed
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 21 of 35
Corrosion Evaluation of Metric Precision Steel Pipes for Vendor
Comparative Assessment (3 months)
Project Description:
Several hydraulic pipes within a prototype machine have been discovered to portray internal
rusting characteristic. Further root‐cause study has exposed an oversight by the supplier
whereby these inner pipes were unprotected via oil‐flushing before shipment. Exposure to
high salinity and humid conditions during sea‐freight has degraded pipes inner surfaces
where passivation protection was not applied.
The sole aim for this test is to get a progressive overview of pipe samples from two (2)
different vendors & their response to salty16
environment.
Engineering
Standard
Skill Segment
ISO 9227, ISO 14993, ISO 2081, ISO 10289 & NACE
Project Planning, Corrosion Study, Testing & Technical Report
Challenges Reproducing marine environment within an in-house test facility
Scope of work:
1. BED
� Conceptual study, planning & execution of Environmental Test to allow the following
parameters to be evaluated:
o Corrosion resistance – In-house salt spray test in accordance with ISO 14993
o Mounting orientation & location – Comparative evaluation on corrosion rate
16 The salt solution used is with 50g/l ±5g/l composition as stipulated in ISO14993 (solution preparation ONLY).
1
2
4
3
Figure 10: 1 - Dimensional verification, 2&3 - Comparison on corrosion outlook between two
suppliers, 4 - Salt spray test setup
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 22 of 35
2. Testing & Documentation
� Initial sample tagging & test fixture erection
� Supplementary assessment – Visual aesthetics, deburring quality & dimensional
verification
� Physical & visual inspection of coating performance as per dictated in ISO 10289
3. Documentation
� Technical report to recommend relevant counter measures to curb future rust initiation
Outcome:
1. Comparative assessment provides firm evidence in which a complete coating (inner & outer)
prevail with lower oxidation characteristics (rust distribution & class rating).
2. To avoid reoccurring predicament only this type of coating should be used on prototype
piping for hydraulic distribution lines
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 23 of 35
Evaluation of Anti-Rust Compound for Product Comparative
Assessment – Dinitrol & Techtyl (3 months)
_
Project Description:
Anti‐rust compound is being widely used in Bromma’s production facility to curb rust initiation on
unpainted steel surfaces and hydraulic connectors. A cost driven project to outsource & substitute the
current compound with an alternative option.
Engineering
Standard
Skill Segment
ISO 9227, ISO 14993, ISO 2081, ISO 10289 & NACE
Project Planning, Corrosion Study, Testing & Technical Report
Challenges A dynamic & thorough assessment program
Scope of work:
1. Testing & Documentation
� Planning & execution of:
o Visual & Physical Inspection – Features such as compound clarity, opaqueness
& tackiness upon touching are visually & physically inspected
o Compound Removability – Supplementary test to measure removability of each
compound when subjected to a common industrial solvent
o In-House Salt Spray - To accelerate the rusting process salt mist17
were sprayed
on a twice/day basis
� Collaboration with SIRIM for 240 hours of accelerated salt spray exposure
� Technical report to propose rejection/approval of the new anti-rust compound tested
Outcome:
Both in-house & external assessment converged towards an outcome; Dinitrol outperforms its
counterpart when it comes to protecting components against further rust propagation
17 The salt solution used is with 50g/l ±5g/l composition which adhered to ISO 14993 (solution preparation ONLY).
1 2
3
Figure 11: 1 - Test samples after tagging, 2 - Compound residual post application, 3 - End result for
after salt spray test
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 24 of 35
Evaluation of Oil Level & Temperature Indicator for Vendor
Comparative Assessment – IFM & Hemomatik (2 months)
_
Project Description:
LT8022 is an electronic level and temperature sensor by IFM supplier whereby its performance
characteristics to be tested against the pre-existing Hemomatik brand. Temperature range, liquid level
reading and drop test to be performed in-house. Delegation of vibration & shock response certification
to SIRIM.
Engineering Standard
Skill Segment
EN 60068-2-27-Ea & EN 600068-2-6-Fc
Autodesk Inventor 3D & Technical Report
Challenges Overall comparative assessment
Scope of work:
1. Testing & Documentation
� Planning & execution of:
o Simulation Test – Subjection to 3D simulation & physical predictive
experimentation to understand constraint, fitting tolerance & micro-interference
with other components
o Functional Test – Comparison on reading precision & accuracy
o Drop Test - To match realistic spreader operating condition during container
loading/unloading
� Collaboration with SIRIM for the following verification:
o Sinusoidal Vibration - Adhered to EN 600068-2-6-Fc
o Shock Response - Adhered to EN 60068-2-27-Ea
� Technical report to include approval/rejection of tested components
Outcome:
Rejection of the new product for production use as it fell short in majority of the critical merits
1
1
Figure 12: 1 - 3D simulation showing micro-interference, 2 - Performance evaluation post external
SIRIM test
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 25 of 35
Evaluation of Oil Heater for Vendor Comparative Assessment
EVT & AVAK (1 month)
_
Project Description:
In brief an immersion heater is used as a direct contact heating method of oil within reservoir. AVAK-
11357 is an immersion heater from AVAK whereby its performance characteristics will be tested
against pre-existing EVT brand.
Skill Segment Autodesk Inventor 3D, NDT & Technical Report
Challenges Overall comparative assessment
Scope of work:
1. Testing
� Planning & execution of:
o Simulation Test – Subjection to 3D simulation & physical predictive
experimentation to understand constraint, fitting tolerance & micro-interference
with other components
2. Documentation
� Technical report to include approval/rejection of the new component
Outcome:
Rejection of new product due its dimensional non-compliance with spreader reservoir design
1
3
2
4
Figure 13: 1&2 - 3D simulation depicting possible interference, 3 - One to one visual comparisons,
4 - Dimensional checking procedure
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 26 of 35
Evaluation of Hydraulic Hoses & Clamps for Suitable
Pairing Selection (2 months)
_
Project Description:
In general a clamp kit is used to ensure a tight hold on the hydraulic hose as well as providing
mechanical mating between hose and the spreader's body. It is also used to absorb shock and vibration
caused by fluid surges within pipes, tubes and hoses in both mobile and stationary applications.
Engineering Standard
Skill Segment
DIN 3015
Dimensional Measurement & Technical Report
Challenges Resource planning for testing on spreader
Scope of work:
1. Testing
� Planning & execution of:
o Physical Fitting & Mounting – To observe mating characteristics of each clamp
against their respective hoses on the spreader
o Functional Test – Mating characteristics when hoses were pressurized under
operating pressure
2. Documentation
� Technical report to include approval/rejection of each hose-clamp combinations
Outcome:
Recommendation to revise of a number of hose-clamp pairs due to unsatisfactory clamping attribute
1
2
3
Figure 14: 1 – The elementary constituents of a DIN 3015 clamp, 2 - Range of clamps to be tested, 3 – Fitting test onto a production spreader
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 27 of 35
Performance Evaluation of Non-Metallic Dampers
- A Comparative Assessment (18 months)
Project Description:
Bromma’s Spreaders are equipped with landing buffer attached between the main frame and
the telescopic beam unit (TBU). It served as shock absorbers between the telescopic beam &
the main beam; dampening excessive collision during operation.
For any landing buffer test, the passing upper limit shall be 75,000 cyclic loads under 12T
pressure. The sample shall NOT have any resin detachment nor do any major disfigurements
that will affect its dampening function.
Skill Segment Project Planning, Fatigue Testing & Technical Report
Challenges Prolonged fatigue test duration, continuous assessment,
test bench failure due to fatigue
Scope of work:
1. Testing
� Conceptual study, planning & execution of Fatigue Test
� The scope of evaluation shall cover the following province:
o Fatigue life evaluation under continuous cyclic loading
o Static & dynamic understanding of the material under lubricated conditions
� Physical & visual inspection of rubber & resin performance
2. Documentation
� Technical report to include approval/rejection of each samples
Outcome:
All samples were showing a wide performance variation & similar resin detachment modes. Only
certain natural rubber buffer samples exceeded the required approval threshold of 75,000 cycles
1
2
3
Figure 15: 1 - Buffer sample with applied grease, 2 - Hydraulic press fixture, 3 – A failure mode showing resin detachment
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 28 of 35
Evaluation of Sheave Wheels for Vendor Comparative Assessment
(1 month)
Project Description:
In essence a sheave wheel works in the same principle as a mechanical pulley. In spreader
operation it is utilized to regulate wire ropes that hold a spreader to its respective crane. For
this test, four sheave wheel units from a new supplier will be evaluated against the pre-
existing brand; an indirect process for procurement leverage.
Engineering Standard
Skill Segment
ISO 5817 & ISO 6520-1
CMM, Welding Defects, Fatigue Test & Technical Report
Challenges Non Destructive Test (NDT) limited to visual assessment
Scope of work:
1. Testing & Documentation
� Planning & execution of:
o Functional test – Collaboration with SIRIM to utilize an equipped facility
o Dimensional Verification – with the aid of a coordinate measurement machine
o Visual comparison – Detection of welding imperfection (ISO 6520-1)
� Technical report to include approval/rejection of the tested components
Outcome:
Rejection of new samples due to unsatisfactory dimensional tolerance & fabrication
1
2
3
Figure 16: 1 - Relative location of sheave wheel w.r.t spreader & crane,
2 – A Draft sketch depicting fatigue test setup, 3 – Test samples
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 29 of 35
Provision of Functional Test for Guide Block & Twistlock Arm
for Vendor Comparative Assessment (1/2 months)
Project Description:
A request for a functional test on a number of guide blocks & twistlock arms by IQC department.
The goals are as follows:
1. Detection of visible defects on samples characterize by the typical deformities18
2. Verifying welding joins are absence from defects that could shorten life cycles
3. Retrieving relevant dimensions from samples via coordinate measurement machine (CMM) &
cross‐checking with respective component drawings
Engineering
Standard
Skill Segment
ISO 5817 & ISO 6520-1
CMM, Welding Defects, Fatigue Test & Technical Report
Challenges Non Destructive Test (NDT) limited to visual assessment
Scope of work:
1. Testing
� Planning & execution of:
o Dimensional verification – With the aid of a coordinate measurement machine
o Functional Test – in house test fitness for purpose
o Field Test – On selected samples under actual operating conditions
� Visual comparison & detection of welding imperfection coherent with ISO 6520-1
2. Documentation
� Technical report to include approval/rejection of the tested components
Outcome:
Rejection of new samples due to unsatisfactory welding characteristics; imperfection in:
1. Incorrect weld toe – Imperfection ISO 6520-1 (505)
2. Excessive asymmetry – Imperfection ISO 6520-1 (512)
3. Insufficient throat thickness - Imperfection ISO 6520-1 (5213)
18 Corresponding to scratches, dings and unusual marks on the metal surface
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 30 of 35
Provision of Functional Test for Hydraulic Leakage Verification
on Hose Assemblies- (1/2 months)
Project Description:
A request for a functional test on hydraulic hoses foreseen to be faulty was issued by IQC department.
Test aims are as follows:
1. Detection of visible defects on hoses characterize by the typical deformities such as stretched
marks, abrasion on rubber & dings inside metal connectors
2. Verifying hoses are in usable state via pressurizing to their allowable rated pressure
Engineering
Standard
Skill Segment
ISO 6606, ISO 13184 (Pressure Decay Technique - EN 1779)
& ISO 17165-2 (Appendix A.1)
Hydraulic Fluid Power & Technical Report
Challenges Resource limitation19
Scope of work:
1. Testing
� Resource coordination & initial assembly setup
� Planning & execution of Pressure Decay Test – According to EN 1779
2. Documentation
� Technical report to include approval/rejection of the tested samples
Outcome:
Approval of samples for production use due to satisfactory pressure retention
19 At the time of this test, all usable hydraulic pump sets were occupied with dedicated test. An alternative way forward was
to scavenge & repair a faulty pump from an obsolete spreader unit.
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 31 of 35
Provision of Functional Test for Hydraulic Leakage Verification on
RWG Valves & Manifold Blocks (1/2 months)
Project Description:
A request for a functional test on valves & manifold blocks foreseen to be faulty was issued by IQC
department. The aims of this test is to verify the components are in usable state via pressurizing to
their allowable rated pressure.
Engineering Standard
Skill Segment
ISO 13184 (Pressure Decay Technique - EN 1779)
Hydraulic Fluid Power & Technical Report
Challenges Root cause analysis & failure mode detection
Scope of work:
1. Testing
� Resource coordination & initial assembly setup
� Planning & execution of Pressure Decay Test – According to EN 1779
2. Documentation
� Technical report to include approval/rejection of tested samples
Outcome:
Approval of samples for production use due to satisfactory pressure retention
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 32 of 35
Marine Machinery Design - Spreader
Aug 10 – July 12
“Devising mechanical machinery designs,
for shipping terminal needs”
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 33 of 35
Project Description:
A spreader (red machine in above picture) is a device used for lifting containers and unitized cargo. It
is commonly used for containers that have a locking mechanism at each corner castings. A spreader
can be used on a container crane, a straddle carrier and with any other machinery to lift containers.
Engineering
standard
Skill Segment
EN 15056, ISO 2553, ISO 13920, ISO 2768, ISO 1302, DIN 3015,
ISO 17165-2, ISO 4406
Sheet Metal Design, Welding, Hydraulic Fluid Power, Project
Management, AutoCAD 2D, Autodesk Inventor 3D
Challenges Multiple project coordination, last minute technical amendments by
clients
Scope of work:
1. BED & DE
� Conceptual and cross reference study based on client’s hydraulic P&ID, headblock20
dimensions, critical component request & painting specifications
� Detail design which leading to preparation of
o General assembly (GA) drawings – Specifying painting requirements, safety
decals & critical parameter notations to aid quality control checking
o Hydraulic schematics – Depicting location of pump, flow dividers, control valves
and other auxiliary components which are fundamental to a spreader operation
o Bill of material (BOM) – For procurement & planning during initial stage of
design. A production check-list during assembly of the spreader unit
2. Procurement Support
� Providing technical steer to sourcing in terms of special components with long lead time
– mechanical & hydraulic items
3. Documentation
� Operational manuals co-ordination between technical writer and sales-force
20 A load bearing mechanical device that act as an intermediate in pairing both quay crane & spreader
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 34 of 35
Project List:
1. Local - Malaysia
� ZPMC - Westport, Malaysia – Twin ship to shore
2. International
� Barbados Port Inc. : Single ship to shore spreader
� APM Terminal, Mexico : Twin electric-yard spreader
� DP World - Caucedo, Spain : Single ship to shore spreader
� Suez Canal Container Terminal, Egypt : Twin yard spreader
� ZPMC - Lazaro Cardenas, Mexico : Twin electric-yard spreader
� PSA - Sical Terminal, India - In charge of designing hydraulic system
� ZPMC - WWI, India : Twin electric-yard spreader with new hoisting section
� Terminal de Contentores de Leixoes , Portugal: Twin ship to shore spreader
� Konecranes - Nutep, Russia : Single yard spreader with cold climate structure
� ZPMC - Nansha II, China : Twin ship to shore spreader with new hoisting section
� ZPMC - TESCA, Columbia : Twin electric-yard spreader with new hoisting section
� Gazal Logistics - Umm Qasr, Iraq : Single yard spreader with new hoisting section
� Port of New Orleans, USA : Twin ship to shore spreader with new hoisting section design
� Kocks Krane GmbH - ITC Terminal, Vietnam : Single yard spreader with impact
protection
� Libherr - Petrolesport, Russia : Single ship to shore spreader with ergonomic ladder
design
� SANNY Group Co. - TCDD Izmir Turkey Twin electric-yard spreader with new hoisting
section
� Mitsui - Exolgan, Argentina : Twin electric-yard spreader with ergonomic access holes &
handrail
� Konecranes - Port of Klaipeda, Lithuania : Twin electric-yard spreader with cold climate
structure
Achievements: ✔ Laid groundwork of the 1st hydraulic-headblock order - hydraulic schematics ✔ Design-revamped an existing sensor technology into 2nd generation spreaders
Lukman Alhakim
Project Portfolio � (M) 013-477 9922 � [email protected]
Page 35 of 35
Recommendations: