Volume 8 – Mechanical and Electrical Services - Malaysia Geoportal

GOVERNMENT OF MALAYSIA 

DEPARTMENT OF IRRIGATION 

AND DRAINAGE 

Volume 8 – Mechanical and 

Electrical Services 

Jabatan Pengairan dan Saliran Malaysia 

Jalan Sultan Salahuddin 

50626 KUALA LUMPUR

DID MANUAL VOLUME 8 

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. 

March 2009 

i


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 

ii March 2009


Steering Committee: 

Acknowledgements 

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. 

March 2009 

iii


Registration of Amendments 

Amend 

No 

Page 

No 

Date of 

Amendment 

Amend 

No 

Page 

No 

Date of 

Amendment 

iv March 2009


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 

Chapter 2 

Chapter 3 

Chapter 4 

Chapter 5 

Chapter 6 

Chapter 7 

Chapter 8 

Chapter 9 

Chapter 10 

Pumping Installation 

Gate Design 

Ground Water Facilities 

Safety and Health 

Plant Management and Control 

Energy Efficiency in Management Of M&E Installation 

Electrical Service 

Dredger 

Asset Management 

Introduction to SCADA and Automation System 

March 2009 

v


List of Volumes 

Volume 1 











FLOOD MANAGEMENT 

RIVER MANAGEMENT 

COASTAL MANAGEMENT 

HYDROLOGY AND WATER RESOURCES 

IRRIGATION AND AGRICULTURAL DRAINAGE 

GEOTECHNICAL MANUAL, SITE INVESTIGATION AND ENGINEERING SURVEY 

ENGINEERING MODELLING 

MECHANICAL AND ELECTRICAL SERVICES 

DAM SAFETY, INSPECTIONS AND MONITORING 

CONTRACT ADMINISTRATION 

CONSTRUCTION MANAGEMENT 

vi March 2009


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 

March 2009 

vii


TNB 

TSHD 

USBR 

Tenaga Nasional Berhad 

Trailing Suction Hopper Dredge 

United States Bureau Of Reclamation 

viii March 2009

CHAPTER 1 PUMPING INSTALLATION

Chapter 1 PUMPING INSTALLATION 


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 

March 2009 1-i


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 

List of Figures 

1-6 

1-10 

1-18 

1-22 

1-27 

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 

1-ii March 2009


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 

March 2009 

1-iii


(This page is intentionally left blank) 

1-iv March 2009

1.1 TYPE OF PUMPS USED IN DID 


1 PUMPING INSTALLATION 

Generally, most of the pumps used in DID are high volume - low head type. Mixed-flow and axialflow 

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 

March 2009 1-1


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 

1-2 March 2009


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 longshaft 

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 

March 2009 1-3


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. 

1-4 March 2009


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. 

March 2009 1-5


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. 

Specific speed 

range (Ns) – metric 

unit 

Head (m) 

Table 1.1 Pump Characteristics for Various Types Of Pump 

Pump Type 

Radial / Francis Mixed-flow Axial- flow 

Radial : 10 – 60 

Francis: 30 - 90 90 - 160 > 160 

High head, 

18 – 300 

Moderate head, 

9 - 18 

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. 

- 

Low head, 

3 – 9 

Yes, power curve 

falls rapidly with 

flow. 

Suction lift High Moderate Low 

General 

Heavy and higher Moderate 

Smaller and 

equipment cost 

cheaper 

- 

1-6 March 2009


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. 

March 2009 1-7


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. 

1.4 PUMPING ARRANGEMENTS 

Fig. 1.5 Pump performance characteristic 

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. 

1-8 March 2009


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. 

March 2009 1-9


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) 

110 

130 

160 

220 

Full load current 

(Amps) 

180 

213 

262 

360 

No. of pumps used 

(For single chamber substation) 

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 L x Q 1.85 

(1.1) 

D 4.87 x C 1.85 

Where Hf = Friction losses in the pipeline (m) 

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 V 2 / 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 / sec 2 ) 

1-10 March 2009


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 backup 

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. 

March 2009 1-11


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

Fig. 1.7 attached. 

Scheme Pumping 

Determine no. of pumping units 

required and pump capacity (Qa) 

Preliminary plant layout 

Estimate total head 

Motor speed (rpm) 

1500, 1000, 750, 

500 

Assign pump speed (Na) 

(Qa, Ha & 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 

No 

Plot pump and system H-Q curve, 

determine efficiency, power and NPSH 

required 

Is the efficiency 

satisfactory 

No 

Check condition NPSH available > NPSH 

No 

If Hb ≠ Ha 

Reassess total head 

Hb ≈ Ha 

Preliminary pump selection completed 

Figure 1.7 Pump Selection Flow Chart 

1-12 March 2009


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. 

March 2009 1-13


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. 

1-14 March 2009


Fig. 1.8(a) Typical examples of suction pumps 

March 2009 1-15


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. 

1-16 March 2009


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 

March 2009 1-17


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 

1-18 March 2009


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) 

March 2009 1-19


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 

1-20 March 2009


Fig 1.11 Typical Pumping Station General Layout 

March 2009 1-21

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 

Maintenance 

Good trash handling 

capacity because of its 

continuous raking-up 

operation 

Submerged sprockets, 

requiring frequent 

attention and difficult 

to maintain. 

Frequent adjustment 

and repair of chains. 

Limited trash 

handling capacity 

because of its 

reciprocating action 

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. 

Trash handling 

capacity is affected 

due to reciprocating 

action, unless wider 

raking attachment is 

used. 

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. 

1-22 March 2009


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) 

b) Overhead Crane 

Fig 1.12 Stationary Screen General Layout 

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. 

March 2009 1-23


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. 

1-24 March 2009


Fig 1.14 Stoplog General Arrangement & Construction 

March 2009 1-25


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. 

1-26 March 2009


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 

Permissible Tolerances 

Standard 

Pump capacity Pump head Pump Efficiency 

ISO 2548 Class C ± 7% of Q rated ± 4% of H rated - 5% of rated 

efficiency 

ISO 3555 Class B ± 4% of Q rated ± 2% of H rated - 2.8% of rated 

efficiency 

ISO 9906 Grade 2 

(Pumps above 10kW) 

± 9% of Q rated ± 7% of H rated - 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. 

March 2009 1-27


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 ------------- 2 nd Grade Driver for each shift. 

Engine 100 – 500 hp ------------ 1 st 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; 

1-28 March 2009


- 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. 

March 2009 1-29



1-30 March 2009


APPENDIX 1A 

ALIGNMENT CHART FOR FLOW IN PIPES. HAZEN-WILLIAMS FORMULA 

March 2009 1A-1


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. 

1A-2 March 2009


(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 

March 2009 1A-3



1A-4 March 2009

1 

CHAPTER 2 GATE DESIGN

Chapter 2 GATE DESIGN 



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 

March 2009 2-i


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 

2-ii March 2009




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 



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 

March 2009 

2-iii



2-iv March 2009


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 

March 2009 2-1


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

Figure 2.2 Spillway Gates 

2-2 March 2009


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 

March 2009 2-3


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 

2-4 March 2009


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 

March 2009 2-5


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 

2-6 March 2009


Figure 2.9(b) Aluminium Roller Gate 

March 2009 2-7


Figure 2.9(c) Aluminium Roller Gate 

2-8 March 2009


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). 

March 2009 2-9


Some common radial gate sizes are:- 

6m X 1.5m(h) 

5m X 1.5m(h) 

Figure 2.11 Radial Gate (Overflow Type) 

2-10 March 2009


b) Bottom hinged flap gate (Tilting Gate) 

Figure 2.12 Radial Gate (Breastwall Type) 

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). 

March 2009 2-11


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). 

2-12 March 2009


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. 

March 2009 2-13


b) High pressure slide gate (Sluice gate) 

Figure 2.16 Slide 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. 

2-14 March 2009


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 facehead. 

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. 

March 2009 2-15


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). 

2-16 March 2009


2.2.5 Stop logs and Bulkhead Gates 

Figure 2.20 Rubber Flex Valve 

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 

March 2009 2-17


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). 

2.3 GATE DESIGN 

2.3.1 General 

Figure 2.22 Bulkhead 

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 

2-18 March 2009

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:- 

March 2009 2-19


Table 2.1 Corrosion Allowance For Plate Thicknees 

Place Skin Plate Other Main Members 

Water contact face or abrasion One Face Both Faces Both Faces (mm) 

face 

(mm) 

(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 

Slide / sluice gate 

Stoplog / bulkhead gate 

1/800 of span 

1/1200 of span 

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:- 

2-20 March 2009


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. 

March 2009 2-21

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, 

(i) Rolled steel for 

general structures 

BS 4360, BS4, 

BS4848 

43, 50 

stiffeners, arms etc) (ii) Stainless Steel BS 970 304 

(iii) Marine Alloy 

Aluminium 

BS 1470 - 77 

NE8M, 

NS8M 

Track base or embedded 

guide 

Rolled steel for general 

structures 

BS 4360 

43 

Seal seat, sill beam 

Stainless Steel 

BS 970 

316 

Gate Wheel / Guide rollers 

Cast Iron 

Cast Steel 

BS 1452 

BS 3100 

Gr 220 

ASTM A27 

60-30 

Rubber Seal 

Moulded natural or 

synthetic rubber 

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: 

2-22 March 2009


Table 2.3 – Materials Used For Penstock 

Component Materials Standard Grade 

Frame and gate Grey cast iron 

BS 1452 220 

Spheroidal graphite iron BS 2789 420/12 

Stem 

Stainless steel 

BS 970 

316 S16 

Stem couplings 


BS 970 

316 S16 

Stem Guides 

Spheroidal graphite iron with 

phosphor bronze lining 

BS 2789 

420/12 

Thrust/Operating 

nuts 

Gunmetal 

Phosphor bronze 

BS 1400 

BS 2874 

LG2 

CZ 114 

Seats 

Gunmetal 


BS 1400 

BS 2874 

LG2 

CZ 114 

Seals 

Gunmetal 


BS 1400 

BS 2874 

LG2 

CZ 114 

Pedestal 

Spheroidal graphite iron 

BS 2789 

420/12 

Bolts, nuts and 

anchor bolts 


BS 970 

316 S16 

Handwheel 

Grey cast iron 

BS 1452 

220 

Identification plate 

and screws 


BS 970 

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. 

March 2009 2-23


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:- 

1 st coat Epoxy Primer DFT 50 micron 

2 nd coat Coaltar Epoxy DFT 100 micron 

3 rd coat Coaltar Epoxy DFT 50 micron 

For hot dip galvanizing protection, BS729 shall be adhered to as follows:- 

Material thickness 

more than 5mm 

less than 2mm 

Min. coating weight 

610 g/m² (100 micron) 

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) 

2-24 March 2009

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 multistage 

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. 

March 2009 2-25


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. 

2-26 March 2009


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. 

March 2009 2-27



2-28 March 2009

1.0 GENERAL 

2.0 SCOPE 

3.0 REFERENCE 

4.0 RESPONSIBILITIES 


APPENDIX 2A 

SAMPLE METHOD STATEMENT 

FOR TILTING GATE AND HYDRAULIC CYLINDER INSTALLATION 

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 

TABLE OF CONTENTS 

March 2009 2A-1


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. 


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. 


List of relevant reference drawings 


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. 

2A-2 March 2009


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. 


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. 


Refer to Job Safety Analysis 

12.0 QUALITY 

All inspection shall be in accordance to the approved Inspection and Test Plan. 

March 2009 2A-3


APPENDIX 2B 

METHOD STATEMENT FOR TILTING GATE GUIDE INSTALLATION 


1.0 GENERAL 

2.0 SCOPE 

3.0 REFERENCE 




7.0 MANPOWER 

8.0 SEQUENCE OF WORK 


10.0 APPROVAL 


12.0 QUALITY 

2A-4 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. 


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. 


Relevant reference drawing 


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. 

March 2009 2A-5


a) Sill Beam 

i) There are two stages to the sill beam installation, namely, 1 st stage and 2 nd stage concreting. 

ii) The twagger palate (2nos) are installed during the 1 st stage, followed by the 2 nd 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 2 nd 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 

iv) 

frame is a special jig designed to give rigidity to the gate guide prior to concreting) 

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 tierods. 

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. 


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. 

2A-6 March 2009



Refer to the Job Safety Analysis 

12.0 QUALITY 

All inspection shall be in accordance to the approved Inspection and Test Plan (ITP). 

March 2009 2A-7

1.0 PURPOSE 


APPENDIX 2C 

TESTING & COMMISSIONING PROCEDURES FOR TILTING GATE 



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 

2A-8 March 2009


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. 

March 2009 2A-9


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. 

2A-10 March 2009


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 

March 2009 2A-11


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 

Section 1 

Compiled References 

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 


Section 2 

Manufacturers’ Operation and Maintenance Instruction Manual 

2.1 Hoist equipment 



2.4 Generator diesel engine 


Section 3 

Manufacturer’s spare part lists 

3.1 Gate and hoist components 

3.2 Gantry crane components 

3.3 Generator components 


Section 4 

Factory and Site Test Reports 

4.1 Gate and hoist system 

4.2 Stoplog system 


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 

2A-12 March 2009


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 

March 2009 2A-13



2A-14 March 2009

CHAPTER 3 GROUND WATER FACILITIES

Chapter 3 GROUND WATER FACILITIES 



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 

March 2009 3-i




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 

3-ii March 2009



3 GROUND WATER FACILITIES 

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 

March 2009 3-1

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. 

3-2 March 2009


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. 

March 2009 3-3


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. 

3-4 March 2009


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. 

3.8 BOREHOLE TEST 

3.8.1 Depth measurement 

Fig. 3.4 Sampling for Flow 

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’. 

March 2009 3-5

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. 

3-6 March 2009


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. 

March 2009 3-7


Steel casing offers superior strength and resistance to mechanical damage. Plastic and fibrecomposite 

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. 

3-8 March 2009


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. 

March 2009 3-9

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. 

3-10 March 2009

CHAPTER 4 OCCUPATIONAL SAFETY AND HEALTH MANAGEMENT SYSTEM

Chapter 4 OCCUPATIONAL SAFETY AND HEALTH MANAGEMENT SYSTEM 



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 

March 2009 4-i



4-ii March 2009


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; 

March 2009 4-1


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. 

4-2 March 2009

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. 

March 2009 4-3


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. 

4-4 March 2009

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 

March 2009 4-5


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 

4-6 March 2009


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. 

March 2009 4-7


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 

4-8 March 2009


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 

March 2009 4-9


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 firefighting 

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 

4-10 March 2009

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. 

March 2009 4-11



4-12 March 2009

CHAPTER 5 PLANT MANAGEMENT AND CONTROL

Chapter 5 PLANT MANAGEMENT AND CONTROL 



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 

March 2009 5-i




5.1 

5.2 

Mechanical Plan Records 

Maintenance Personnel Chart 

5-2 

5-5 

5-ii March 2009



5 PLANT MANAGEMENT AND CONTROL 

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. 

March 2009 5-1


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 

5-2 March 2009


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. 

March 2009 5-3

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. 

5-4 March 2009


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 

March 2009 5-5


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. 

5-6 March 2009


APPENDIX 5A PLANT REGISTER 

APPENDIX 5A 

March 2009 5A-1


APPENDIX 5B1 PLANT MOVEMENT RECORD 

APPENDIX 5B1 

5A-2 March 2009


APPENDIX 5B2 PLANT MOVEMENT RECORD 

APPENDIX 5B2 

March 2009 5A-3


APPENDIX 5C ANNUAL RETURN ANALYSIS 

APPENDIX 5C 

5A-4 March 2009


APPENDIX 5D MONTHLY RETURN 

APPENDIX 5D 

March 2009 5A-5


APPENDIX 5E DAILY RUNNING RECORDS 

APPENDIX 5E 

5A-6 March 2009


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. 

March 2009 5A-7


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. 

Prepared by J.J. LKT. 

t.t. 

Checked by: J.J.K. II 

5A-8 March 2009


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. 

March 2009 5A-9


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. 

5A-10 March 2009


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 Monthly inspection on damaged surface. All the debris 

Main Roller track 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 

March 2009 5A-11


(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. 

5A-12 March 2009


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 

Actuator / Gearbox 

Greasing points (rope-drum) 

Recommended Lubricant 

Shell Spirax EP2 

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. 

March 2009 5A-13


APPENDIX 5I PLANT MAINTENANCE AND CONTROL CHART 

APPENDIX 5I 

5A-14 March 2009

CHAPTER 6 ENERGY EFFICIENCY IN MANAGEMENT OF M&E 

INSTALLATION

Chapter 6 ENERGY EFFICIENCY IN MANAGEMENT OF M&E INSTALLATION 




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 

March 2009 6-i




6.1 

6.2 

Typical Solar Cell 

Typical PV Powered Motorised Water 

Gate Control 

6-8 

6-9 

6-ii March 2009


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:- 

March 2009 6-1


- 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. 

6-2 March 2009


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 

March 2009 6-3


• 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. 

6-4 March 2009


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, sitespecific 

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. 

March 2009 6-5


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 

6-6 March 2009


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. 

March 2009 6-7


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. 

6-8 March 2009


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. 

Measurement value 

Fig. 6.2 Typical PV Powered Motorised Water Gate Control 

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. 

January 2009 6-9

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. 

6-10 March 2009

CHAPTER 7 ELECTRICAL SERVICES

Chapter 7 ELECTRICAL SERVICES 




................................................................................................................... 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 

March 2009 7-i


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 

7-ii March 2009




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 

March 2009 

7-iii



7-iv March 2009


7 ELECTRICAL SERVICES 


Electrical installation work is generally governed by The Electricity Supply Act 1990, and Electricity 

Supply Regulation 1994.In addition, The IEE Wiring Regulations 16 th 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 16 th 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. 

March 2009 7-1


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. 

7-2 March 2009


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 m 2 

Therefore illumination, Eav = incident light (7.1) 

Area 

= 3650 

3 x 3 

= 405.56 

= 406 lux (lm per m 2 ) 

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 m 2 , 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) 

March 2009 7-3


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) 

7-4 March 2009


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 

Lighting 

Air cond. System 

Future growth, say 20% 

Office Block 

0.9W per sq. foot 

4.7 W per sq. foot 

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 16 th 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. 

March 2009 7-5


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. 

7-6 March 2009


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. 

March 2009 7-7


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 Size of Wire 

No. of Point per Circuit 

Rating 

5A 1.5mm 2 8 Nos. of lighting or fan points or 1 Nos of 5A 

15A 2.5mm 2 1 Nos. 13A switch socket outlet 

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

30A(ring) 2.5mm 2 10Nos 13A s/s/o provided they are all located 

within an area of more than 1,000 sq. ft. 

30A(radial) 4.0mm 2 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. 

7-8 March 2009


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. 

March 2009 7-9


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. 

7-10 March 2009


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. 

March 2009 7-11


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. 

7-12 March 2009


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) 

March 2009 7-13


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. 

7-14 March 2009


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. 

March 2009 7-15


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. 

7-16 March 2009


APPENDIX 7A SAMPLE ARRANGEMENT OF LIGHTING IN A BUILDING 

March 2009 7A-1


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. 

7A-2 March 2009


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. 

March 2009 7A-3


APPENDIX 7D SINGLE LINE DIAGRAM OF A SIMPLE INSTALLATION 

Appendix 7-D 

7A-4 March 2009


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 1 st 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 


53kVAx0.85pf 45 

Run 1 st pump and G.L .load 30.13 26 30.13 26 

Total 83.13 71 30.13 26 

Run the 2 pump 


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 


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 


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 3 rd 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 

March 2009 7A-5


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) 

(b) 

Voltmeter 

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. 

7A-6 March 2009


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 

B.3 

B.4 

Change lubricating oil filters half-yearly or 250 hours 

whichever 

occurs first. 

Check hydraulic governor oil level, replenish if 

necessary 

Check hydraulic governor oil at 12 th 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 

March 2009 7A-7


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 

E.1 

E.2 

F 

Electrical System 

Check battery electrolyte level and specific gravity, 

replenish if 

Necessary. 

Check the conditions of the battery charger and / or 

battery 

Charging alternator. 

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) 

(b) 

Low lubricating oil pressure 

- warning and trip 

High lubricating oil temperature 


© High exhaust temperature 


7A-8 March 2009


(d) 

(e) 

(f) 

(g) 

(h) 

(i) 

(j) 

High jacket water temperature 


Low radiator water level 


Fail to start 


Overspeed 


Low batter voltage 


Low fuel level (1st stage) 


Low fuel level (2nd stage) 


(k) Fuel pump runaway 

- warning and trip by shut-off fuel supply 

to the engine 

March 2009 7A-9


APPENDIX 7H SAMPLE SCHEMATIC DIAGRAM FOR POWER SUPPLY SYSTEM 

APPENDIX 7H SAMPLE SCHEMATIC DIAGRAM FOR POWER SUPPLY SYSTEM 

7A-10 March 2009


(continued from previous page) 

March 2009 7A-11



7A-12 March 2009

CHAPTER 8 DREDGER

Chapter 8 DREDGER 



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 

March 2009 8-i




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 



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 

8-ii March 2009


8 DREDGER 


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. 

8.2 USAGE OF DREDGER 

Fig. 8.1 Typical 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. 

March 2009 8-1


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 

8-2 March 2009


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). 

March 2009 8-3


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 500m 3 4000m 3 

Medium sized TSHD 4,000m 3 9,000m 3 

Large sized TSHD 9,000m 3 17,000m 3 

Jumbo TSHD 17,000m 3 35,000m 3 

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. 

8-4 March 2009


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 

Coupling 

System 

Suction / Discharge 

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. 

March 2009 8-5


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. 

8-6 March 2009

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, 

m 3 

Trailing 

suction 

hopper 

dredge 

Cutter suction 

dredge and 

suction 

dredge 

Hydraulic 

unloader 

Barges / 

scows 

Spider / 

Bardge 

Pipeline 

Booster pump 

stations 

Can operate in 

rough seas 

Light to 

moderate sea 

conditions 

(H=1m) 

Operates in 

sheltered areas 

Operates in 


15-30 100 Bottom placement 100,000 – 

500, 000 / 

week 

25 60-80 Discharge of material 

through pipeline or 

loading onto barge 

- - Hydraulically 

removes sediment 

from barges filled at 

other location 

- - Can be loaded or 

unloaded bottom 

placement 

- - Loads barges from 

hydraulic dredge 

- - Land pipeline offers 

flexibility for material 

placement 

Operates in 


Sensitive to 

wave action and 

strong currents 

- - - 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 – 

500, 000 / 

week 

- 

300 – 4, 

000 / 

week 

- 

- 

- 

- 

50, 000 / 

week 

March 2009 8-7

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 


8-8 March 2009


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 

March 2009 8-9


Table 8.3 - Disposal Systems 

Dredge type Disposal Method Comments 

Hopper dredger 

(THD) 

Hopper dredger 

(THD) 


pipeline dredger 

(CSD) 


pipeline dredger 

(CSD) 

Mechanical clam 

shell dredger 

Desiltation and 

water jetting plants 

Excavators, grab 

dredgers and 

bucket suction 

dredgers 

Sea dumping, shore pumping, 

rain bowing, booster station, 

submerged pipeline 

Hopper dredger combined with 

cutter suction – double 

handling, submerged pipelines 

Spider barge, hopper barge, 

hydraulic unloading and 

dredge pipelines 

Hopper barge and second 

cutter suction pipeline dredger 

with submerged pipelines 

Hopper barge and hydraulic 

unloader with submerged 

pipelines 

Displacement of silt through 

pipelines or travel through tidal 

waves 

Barge/truck loading, beach and 

sea walls nourishment 

Maintenance/capital dredging of widening and 

deepening of port channels, beach/sea wall 

nourishment and land reclamation 

Maintenance/capital dredging of widening and 

deepening of port channels, beach/sea wall 

nourishment and land reclamation 

Capital dredging of port channels, harbour berths, 

land reclamation, beach and coastal restoration 

New port projects under capital dredging 

Offshore location operations 

Environmantal effects and siltation near the harbour 

berths 

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. 

8-10 March 2009


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) 

Dredger Operating Cost Per Month 

Rate of Dredging Vol. Per Month @ output 

___(Cu.m/hr) 

based on monthly rental 

(26days) 70%of opr. 

Rate 

26 days x Rate 

4 days x Rate 

Rate 

___ litres X Rate 

Sub -total 

Output(Cu.m/hr) x 16hr x 

26days/mth 

a. Dredger Cost / m 3 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 / m 3 RM 

RM 

RM 

RM 

RM 

RM 

RM 

RM 

RM 

March 2009 8-11


3.2 Speed Boat - Rental & Operation 

Rental and Operational Rate Per Month @ Rate Rate x 26 day/mth RM 

____ (RM/day) 

c. Speed Boat Cost / m 3 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 

d Floating Pipe Cost / m 3 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) 

Rate x 100nos 

RM 

Life span of floater - 10 million cu.m 

e Floater Cost / m 3 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 * 

f Rubber Hose Cost / m 3 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/m 3 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) 

1 x rate. x 1.7 x 70% 

1 x rate.x1.7 

4 x rate x 1.4x100% 

RM 

RM 

RM 

Lab. Assistant - 1 Person @ Rate____(RM/mth) 1x rate x 1.4 x 100% RM 

Accomodation - 2 Nos x monthly rate 

Transportation - 2 Nos x monthly rate 

Others Miscellaneous @ Rate____(RM/mth) 

Rate 

rate 

rate 

RM 

RM 

RM 

Sum 

Sub -total 

RM 

Supervision Cost / m 3 

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 

Rate For Dredging Works Per Cu.M 

RM 

RM 

RM 

RM 

RM 

RM 

8-12 March 2009


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 

2.0 

2.1 

Works (Cu.M): 

Excluding over dredge 

including over dredge 15% 

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 

RM 

a Land Base Pipeline Cost / m 3 RM 

2.2 Machineries & Equipment Land Base 

Bull Dozer - 3 Nos @ Rate____(RM/mth) 

RM 

Fuel cost @ Rate____(RM/litre) 

Excavator - 2 Nos @RM NA/hr 


Wheel Loader - 1 Nos @RM NA/hr 


Generator Set - 2 No @RM NA/mth (20Kw) 


Welding Set - 1 No @RM NA/mth 


Dump Truck- 3 Nos @RMNA/hr (15 tonne) 


Fuel Tank - 10,000 lit Capacity -Rental 

monthly 

3 Nos x rate x 24hrs 

x 26days 

3 Nos x 18lit/hr x 24hrs x 

26days x rate 


x 26days 

2 Nos x18lit./hrx 24hrs 

x 26days x rate 


x 26days 


26days x rate 

2 Nos x rate 

2 Nos x 10 lit/hr x 12hrs 

x26days x rate 

1 Nos x rate 

1 Nos x 5lit/hr x 10hrs 

x 25days x rate 

3Nos x rate x 10hrs x 26days 


26days x rate 

RM 

b Machineries & Equip. Cost / m 3 RM 

sum 

Cu.m 

Cu.m 

Cu.m 

RM 

RM 

RM 

RM 

RM 

RM 

RM 

RM 

RM 

RM 

RM 

RM 

RM 

RM 

March 2009 8-13


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/m 3 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 /m 3 RM 

Rate of Beach Filling & Profiling Works / Cu.M 

( sum a-d) 

Allow for 15% Profit 

Rate For Filling & Profiling Works Per Cu.M 

(RM) 

RM 

RM 

RM 

8-14 March 2009


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 cuttersuction 

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. 

March 2009 8-15


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. 

8-16 March 2009


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 lifesaving 

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’. 

March 2009 8-17


‣ 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. 

8-18 March 2009


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 

March 2009 8-19

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". 

8-20 March 2009


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). 

March 2009 8-21


• 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. 

8-22 March 2009

CHAPTER 9 ASSET MANAGEMENT

Chapter 9 ASSET MANAGEMENT 



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 

March 2009 9-i


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 

9-ii March 2009


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 

March 2009 

9-iii




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 



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 

9-iv March 2009


9 ASSET MANAGEMENT 


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 apaapa 

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. 

March 2009 9-1


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 Badanbadan 

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, pekelilingpekeliling 

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. 

9-2 March 2009


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 undangundang 

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 besarbesaran, 

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. 

March 2009 9-3


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 pegawaipegawai 

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 

9-4 March 2009


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. 

March 2009 9-5


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 

BAB F 

KEHILANGAN 

/HAPUS KIRA 

BAB E 

PELUPUSAN 

TPA 

BAB A 

PENERIMAAN 

BAB B 

PENDAFTARAN 

BAB D 

PENYELENGGARAAN 

BAB C 

PENGGUNAAN, PENYIMPANAN & 

PEMERIKSAAN 

9.4.1 Pendahuluan 

Fig. 9.1 Carta Aliran untuk Tatacara Pengurusan Aset(TPA) 

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. 

9-6 March 2009


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. 

March 2009 9-7


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. 

9-8 March 2009


Fig. 9.2 KEW.PA-1 - Borang Laporan Penerimaan Aset 

March 2009 9-9


9.4.3 Bab B 

9.4.3.1 Pendaftaran 

CARTA ALIRAN 

DAN PROSES KERJA 

LAPORAN TAHUNAN 

HARTA MODAL & 

INVENTORI 

PENGESAHAN 

PENDAFTARAN 

OBJEKTIF 

PENDAFTARAN 

TEMPOH MENDAFTAR 

PENDAFTARAN ASET 

HADIAH 

PENDAFTARAN ASET 

LUCUTHAK 

URUSAN PENDAFTARAN 

ASET ALIH 

BUTIRAN MAKLUMAT 

PUNCA MAKLUMAT 

DOKUMEN PENDAFTARAN 

9.4.3.2 Objectif pendaftaran 

Fig. 9.3 – Carta Aliran untuk Pendaftaran Aset 

• 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. 

9-10 March 2009


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 sumbersumber 

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. 

March 2009 9-11


Kementerian/Jabatan: Pebendaharaan 

Bahagian:Kawalan dan Pemantauan 

Kod Nasional 

Kategori 

Sub Kategori 

Jenis/Jenama/Model 

Buatan 

Jenis dan No. Enjin 

No. Casis/Siri Pembuat 

No. Pendaftaran 

Peralatan ICT 

Komputer 

DELL/L1506 

Malaysia 

DP/NO7N22 

DAFTAR HARTA MODAL 

BAHAGIAN A 

KEW. PA-2 

(No. Siri Pendafataran: KK/BKP10/H/07/1 

Harga Perolehan Asal 

Tarikh Diterima 

No. Pesanan Rasmi Kerajaan 

RM8,500 

13 April 2007 

LO A5624 

KOMPONEN/AKSESORI 

CPU Papan Kekunci 

Monitor Tetikus 

Speaker 

Lokasi 

Tarikh 

Nama Pegawai 

Tandatangan 

Tarikh 

Status Aset 

Nama Pemeriksa 


PKP(P) 

17 April 2007 

Ahmad Hishamuddin 

ƒ 

PENEMPATAN 

PEMERIKSAAN 

Tempoh Jaminan 

Nama Pembekal Dan Alamat 

Compter System Sdn. Bhd 

No. 15, Plaza Low Yatt, Jalan 

Embi 

1 Tahun 

Tandatangan Ketua Jabatan: Ń 

Nama: Noorrizan bt. Shafie 

Jawatan Setiausaha Bahagian 

PELUPUSAN/HAPUS KIRA 

Rujukan Kelulusan 

Tarikh 

Kaedah Pelupusan 


KEW. PA-2 

DAFTAR HARTA MODAL 

BUTIR-BUTIR PENAMBAHAN, PENGGANTIAN DAN NAIKTARAF 

BAHAGIAN B 

Bil. 

Tarikh 

Butiran 

Tempoh jaminan 

Kos (RM) 

Nama dan 


1. 

21.6.2007 

Penggantian CPU 

1 tahun 

1,000 

Fig. 9.4 - KEW.PA-2 - Daftar Harta Modal 

9-12 March 2009


Kementerian/Jabatan: Perbendahraan 

Bahagian: Kawalan dan Pemantauan 

Kod Nasional 

DAFTAR INVENTORI 

KEW. PA-3 

(No. Siri Pendafataran KK/BKP10/I/07/1-5 

Kategori 

Perabot 

Sub Kategori 

Almari 

Jenis 

Almari Buku Bercermin 

Kuantiti 

5 

Harga Perolehan Asal 

RM350.00 sebuah 

Unit Pengukuran 

buah 

Tarikh Diterima 

17 Mei 2007 

Tempoh Jaminan 

1 Tahun 

No. Pesanan Rasmi Kerajaan LO CT3456 

Nama Pembekal dan Alamat 

Tandatangan Ketua Jabatan: Ń 

Syarikat Sri Kenanga Sdn. Bhd. 

Lot 50 Jalan Tuanku Abdul Rahman 

Kuantiti 

1 

1 

No. Siri KK/BKP10/1// KK/BKP10/1// 

Lokasi 

SBKP 

TSBKP(A&p) 

Tarikh 

22 Mei 2007 22 Mei 2007 

Nama Pegawai Noorrizan bt. Tajol Azhar 

Tandatangan Ñ 

Ť 

Tarikh 

22.6.2007 

22.6.2007 

Status Aset Seang 

Seang 

Nama 

Hisham & Hisham & 

Tandatangan & ¥ 

& ¥ 

Nama: Nooorizan bt. Shafie 

PENEMPATAN 

Jawatan; Setiausaha Bahagian 

1 

1 

1 

KK/BKP10/1// KK/BKP10/1// KK/BKP10/1// 

TSBKP(S) Pkp(p) 

PPT(P) 

22 Mei 2007 22 Mei 2007 22 Mei 2007 

Nik Hassan Ahmad 

Henry Chong 

H 

A 

H 

PEMERIKSAAN 

22.6.2007 

22.6.2007 

22.6.2007 

Seang 

Seang 

Rosak 

Hisham & Hisham & Hisham & 

& ¥ 

& ¥ 

& ¥ 

PELUPUSAN/HAPUS KIRA 

Tarikh 

Rujukan 

Kaedah Pelupusan 

Kuantiti 

Lokasi 


3.7.2007 

KK/BDSWP 10/767/2(81) 

Buang 

1 

PPT(P) 

§ 

Fig. 9.5 - KEW.PA-3 - Daftar Inventori 

March 2009 9-13


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 

9-14 March 2009


Table 9.2 Proses Kerja Pendaftaran Aset Alih Kerajaan 

March 2009 9-15


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. 

9-16 March 2009


• 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) 

March 2009 9-17


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 

9-18 March 2009


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. 

March 2009 9-19


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 pegawaipegawai 

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) 

9-20 March 2009

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 bahagianbahagian 

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. 

March 2009 9-21


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 

9-22 March 2009

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 

March 2009 9-23


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 

9-24 March 2009


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. 

March 2009 9-25


9.4.6 Bab F 

9.4.6.1 Kehilangan dan hapus kira 

CARTA ALIRAN DAN 

PROSES KERJA 

TAFSIRAN 

OBJEKTIF 

(e) Tindakan 

Selepas 

Kelulusan 

HAPUS KIRA 

KUASA MELULUS 

URUS SETIA KEHILANGAN 

& HAPUS KIRA 

(d) Laporan 

Akhir 

PROSES HAPUS KIRA 

(c)Jawatankuasa 

Penyiasat 

(b)Laporan 

Awal 

(a)Melaporka 

n 

Kehilangan 

9.4.6.2 Tafsiran kehilangan 

Fig. 9.6 – Carta Aliran untuk Kehilangan dan Hapus Kira 

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. 

9-26 March 2009


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. 

March 2009 9-27


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 

9-28 March 2009


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. 

Pegawai Pengawal hendaklah:- 

12 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). 

March 2009 9-29



9-30 March 2009

CHAPTER 10 SCADA AND AUTOMATION SYSTEM

Chapter 10 SCADA AND AUTOMATION SYSTEM 


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 

March 2009 10-i




10.1 

10.2 

SCADA And Automation System 

Configuration 

Drainage And Irrigation SCADA System 

Network Topology 

10-2 

10-5 

10-ii March 2009


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 

March 2009 10-1


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 

10-2 March 2009


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 

March 2009 10-3


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. 

10-4 March 2009


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: 

March 2009 10-5


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 

10-6 March 2009


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. 

March 2009 10-7


• 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. 

10-8 March 2009


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 noncontact 

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. 

March 2009 10-9


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. 

10-10 January 2009


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. 

March 2009 10-11


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. 

10-12 March 2009


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.) 

March 2009 10-13


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. 

10-14 March 2009


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. 

March 2009 10-15


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. 

10-16 March 2009

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. 

March 2009 10-17


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. 

10-18 March 2009


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 

March 2009 10-19


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 

10-20 March 2009


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 

March 2009 10-21


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 

10-22 March 2009

Volume 8 – Mechanical and Electrical Services - Malaysia Geoportal

Create successful ePaper yourself

Delete template?

Save as template?