A A N N G G K K A A S S A A C C O O N N S S U U L L T T I I N N G G S S E E R R V V I I C C E E S S S S D D N N B B H H D D N N e e w w s s l l e e t t t t e e r r Issue No.1/2013 April –May 2013 Editor Norzana binti Mohd Anuar Committee Member Mohd Mirzan bin Mazlan Mustapha Maarof bin Junid Norafizah binti Abd Rahman Chia Yean Ping Pandima Devi In this issue several interesting topics are featured: 1. Concrete Cut-off Wall for Mengkuang Dam Project by Steven Toh Chin Kok & Norafizah A. Rahman 2. Numerical Modeling for a Concrete Face Rockfill Dam (CFRD) by Steven Toh Chin Kok & Norafizah A. Rahman 3. Solar Hybrid Project for RPS Kemar, Gerik, Perak: ACS’s 1 st fully operational solar hybrid Project, 2 nd biggest solar hybrid in Malaysia by Lau Meng Yong 4. Joint Study of Coastal Flooding at Golok Rivermouth by Norzana Mohd Anuar 5. Tailing Dam for Iron-Ore Mine by Mustapha Maarof bin Junid 6. Catalogue Filing System by Tan Li Zhi 7. A Journey To The North- West of Indo-China – Myanmar by Ng Han Tiong 8. Continuous Improvement by Norafizah A. Rahman BRAINSTORMING 2013 was held on 5 Jan 2013 at Holiday Inn Glenmarie, Shah Alam. All the engineers were invited and we had almost 99% attendance. Our MD, Mr. Khor CH gave a welcoming speech follow-up with Mr. Steven Toh’s ‘Kaizen’s Continuous Improvement’. Other interesting topics were discussed, questioned, and opinions were shared. The primary objective of the exercise was to prepare the engineers on what to expect in the coming years and also the rewards that is within reach with our continuous improvement.
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4. Joint Study of CoastalFlooding at GolokRivermouthby Norzana Mohd Anuar
5. Tailing Dam for Iron-OreMineby Mustapha Maarof binJunid
6. Catalogue Filing Systemby Tan Li Zhi
7. A Journey To The North-West of Indo-China –Myanmarby Ng Han Tiong
8. Continuous Improvementby Norafizah A. Rahman
BRAINSTORMING 2013was held on 5 Jan 2013 at Holiday InnGlenmarie, Shah Alam. All the engineerswere invited and we had almost 99%attendance. Our MD, Mr. Khor CH gave awelcoming speech follow-up with Mr.Steven Toh’s ‘Kaizen’s ContinuousImprovement’. Other interesting topicswere discussed, questioned, and opinionswere shared.The primary objective of the exercise was toprepare the engineers on what to expect inthe coming years and also the rewards thatis within reach with our continuousimprovement.
Hydro-thermally alteredgranite - Whitish Material
Discovered at Site
Structural and Geotechnical
Engineering
Steven Toh Chin Kok1,
Norafizah A. Rahman2
he Expansion of Mengkuang Dam Project,
Pulau Pinang is being implemented under
the 10th Malaysia Plan by the Federal
Government. The existing Mengkuang Dam was
built in 1983 with storage capacity of 22 million
cubic meters. It supplies raw water to Sg Dua
water treatment plant during drought season to
compensate the shortfall of raw water
from Sg. Muda.
The project involves raising of the existing dam by
11m and construction of a 45m high earthfill dam
at the adjacent valley. The
project are to increase the reservoir storage from
22 million cubic meters to 73.5 million cubic
meters and the
raw water
supply capacity
from 300 MLD
to 1000 MLD Sg
Dua water
treatment
plant.
Plastic concrete
cut-off wall is
incorporated in
the design of
the Mengkuang
Dam as a
seepage cutoff system. This would also prevent
internal erosion of the clay core
operation. A flexible and low strength plastic
concrete was selected as seepage barrier to
sustain deformations expected
and to resist erosion if a crack should
T
Concrete Cut-off Wall for
Mengkuang Dam Project
thermally alteredWhitish Material
Discovered at Site
he Expansion of Mengkuang Dam Project,
is being implemented under
the 10th Malaysia Plan by the Federal
The existing Mengkuang Dam was
built in 1983 with storage capacity of 22 million
cubic meters. It supplies raw water to Sg Dua
water treatment plant during drought season to
of raw water abstation
project involves raising of the existing dam by
11m and construction of a 45m high earthfill dam
objectives of the
project are to increase the reservoir storage from
22 million cubic meters to 73.5 million cubic
seepage cutoff system. This would also prevent
of the clay core or piping during
low strength plastic
concrete was selected as seepage barrier to
expected without cracking
and to resist erosion if a crack should happen.
Difficult construction problems were
including excavation through loose
hydrothermally altered granite, residual soils and
embedment of the toe of the wall into a Grade 3
granite rock.
The properties and construction features of the
cut off wall are as per following:
Maximum size of coarse aggregate
Slump between 180mm and 220mm
time of placement
Minimum 28 days unconfined compressive
strength to be 1.20 MPa
Maximum elastic modulus of 800 MPa
Coefficient of permeability equal or below 10
m/s
Construction Features
The thickness of the cut off wall is 600mm.
Bentonite is used as a drilling fluid during
excavation to stabilize trench wall.
The cut off wall is embedded with minimum 1m
key into bedrock.
Implementation issues
construction of the cut off wall
Quarry blasting adjacent the project site posing
risk of curing of the constructed cut off wall.
Risk of leakage from existing dam
construction of new dam and heightening of
existing dam. A comprehensive
measures
are
implemen
ted to
manage
the risks.
Collapse
of trench
during
construction due
to unstable material adjacent to the cut off wall
particularly the hydrothermally altered material.
off Wall for
Mengkuang Dam Project
2
Construction of PlasticConcrete Cut Off Wall
construction problems were encountered
including excavation through loose
ly altered granite, residual soils and
the toe of the wall into a Grade 3
The properties and construction features of the
cut off wall are as per following:
Maximum size of coarse aggregate – 20mm.
Slump between 180mm and 220mm at the
time of placement
Minimum 28 days unconfined compressive
strength to be 1.20 MPa
Maximum elastic modulus of 800 MPa
Coefficient of permeability equal or below 10-9
Construction Features
The thickness of the cut off wall is 600mm.
sed as a drilling fluid during
excavation to stabilize trench wall.
The cut off wall is embedded with minimum 1m
mplementation issues arise during
construction of the cut off wall
adjacent the project site posing
curing of the constructed cut off wall.
Risk of leakage from existing dam – during
construction of new dam and heightening of
A comprehensive mitigating
material adjacent to the cut off wall
particularly the hydrothermally altered material.
3
The unstable materials were removed during
construction of the trench.
Interfaced details and construction sequence of
consolidation grouting, jet grouting and curtain
grouting. A detailed methodology was
developed with input from the contractor for
proper execution of cut off wall.
Structural and Geotechnical
Engineering
Steven Toh Chin Kok1,
Norafizah A. Rahman2
t was in 1895, that the first concrete face rockfill
dam was built in California but the design and
construction have only improved considerably
since the 1970s. Concrete Face Rockfill Dam
(CFRD) is a kind of dam that conceives rockfill as
the supporting structure and concrete slabs on the
upstream slope as the impervious element. In the
early days of CFRD development the design were
empirical which mainly based on previous
experience and on engineers’ judgment. However
it is gradually change to an approach of being
constructed by theoretical analyses and laboratory
and field testing research.
Previous analyses of CFRD were performed mainly
using linear elastic models and most were 2D
analyses. In recent years, non-linear analysis has
become widely accepted and the main analytical
method is either the finite element method (FEM)
or the finite difference method (FDM).
Monitoring the behavior of the existing dam and
analysis of dam instrumentation data after
Phase 1 completion and transfer of water into
new reservoir. This is to ensure the new dam
constructed is safe for operation.
Current Project of Concrete Face Rockfill Dam
- Tawau Dam
Proposed dam site is located about 10 km north of
Tawau township. Land area (679 acre) from dam
construction and reservoir area has been
acquired.
Tawau dam will be designed as concrete face
rockfill dam, 65 m in height. The dam is required
to meet projected raw water requirement of 370
Mld to year 2050.
For CFRD, the stress and deformation properties
of the rockfill and the concrete face slab are the
most important issues regarding dam safety and
performance. In CFRD, settlement of the rockfill
during and after construction can cause
deformation and cracking of the concrete face. In
numerical analysis of CFRDs, the constitutive
model of the rockfill is the most important base of
an analysis. The stress and deformation analyses
of CFRD need comprehensive consideration of
different factors, which include the stress and
deformation relationship, strength properties and
deformation properties and et cetera.
We foresee a great challenge and experience
ahead to precisely predict and simulate the
surface contact and joints between the concrete
slabs, construction steps and reservoir
impounding sequence.
I
Numerical Modeling for a
Concrete Face Rockfill Dam (CFRD)
4
Map to RPS Kemar from Pulau Banding
Midas GTS as the Geotechnical Software Used For
the Concrete Face Rockfill Dam
Midas GTS is all-in-one Finite Element (FE) analysis
software for the use of geotechnical engineering.
It is a total, state of the art solution which has
been developed through integrating all the
functionality necessary for structural analysis for
geotechnical and tunnel engineering.
The software is used for the analysis of
Tawau Dam Project which include stress
analysis reflecting construction stages,
seepage analysis, consolidation, etc.
The model of dam-foundation-reservoir
system can be used for a wide range of
analysis for the Tawau Dam Project such as :-
Civil Infrastructure Project Engineer
Lau Meng Yong
“ACS’s First Fully Operational
Solar Hybrid Project, Second Biggest
Solar Hybrid In Malaysia”
PS Kemar is a remote orang asli settlement
consisting of 15 villages located in the
southern tip of Tasik Temenggor, Gerik,
Perak. It has a total population of 5,000. The main
mode of transport to RPS Kemar is by a 1.5 hours
boat ride from Pulau Banding, Tasik Temenggor
followed by 20 min 4WD from the jetty to RPS
Kemar. An alternative access is by way of a logging
track from Lasah, Sg Siput (travelling time, 8 to 12
hours in wet condition and unusable during very
wet condition).
Prediction of the structural stability and
simulation of any possible failure mechanisms
under a range of loading scenarios (typically
normal operation, flood, earthquake)
Optimization of dam components
Prediction of the behavior of dam under
operation and assessment of their safety.
In an effort to provide a more reliable power
supply to selected remote orang asli villagers, the
Kementerian Kemajuan Luar Bandar dan Wilayah
(KKLW) has implemented the ‘PROJEK BEKALAN
ELEKTRIK LUAR BANDAR (BELB) KE
PERKAMPUNGAN ORANG ASLI 2010-2011’.
R
RPS Kemar
GerikTasik
Temenggor
Pulau Banding
Solar Hybrid Project For RPS
Kemar, Gerik, Perak
5
Arrays of Polycrystalline Solar Panels
Power House
Inverter Control Room
RPS Kemar Solar Hybrid Diagram
KKLW has appointed TNB Energy Services Sdn Bhd
(TNBES), a subsidiary of TNB, as the project
implementer, who in turn has appointed ACS to
undertake the full scope of engineering
consultancy services from detailed design and
tender documentation to contract administration
and construction supervision.
The whole project took 12 months to complete.
One of the major obstacles faced is the logistic
problem. All construction machineries and
materials were transported by barges across the
vast expanse of Tasik Temenggor. This is especially
challenging when the water level of lake was at its
lowest.
The project consists of a solar hybrid station -
combination of solar PV, diesel generators and
battery, with power generating capacity of
850kW. At peak load, the hybrid station is capable
of producing 1.5MW of which 850kW is generated
by the solar PV and 650kW by diesel generators. It
is currently the second largest solar hybrid power
station in Malaysia.
The whole project used a total of 3,696 numbers
of 230W Polycrystalline solar panels and stores
the generated electricity in 960 numbers of
4500kWh batteries. Power generation reverts to
diesel generators during cloudy periods of the day
or when the battery is not able to fully support the
consumer loading. Transformers then step-up the
power from 415V to 11kV and is distributed via 3
main distribution lines. It is then stepped down to
415V before reaching the consumers.
Solar Hybrid system based on photovoltaic is
considered an effective option to electrify remote
and isolated areas far from the national grid such
as RPS Kemar which receives an average of 4.43
kWh/m²/day solar radiation annually.
850kWp Solar PV
1600kVa
Genset
4500kWh Battery
Step-Up Transformers Consumers
Controller
Battery Room
The villagers in RPS Kemar now enjoy 2
electricity supply like the rest of Malaysians
average electricity bill per household ranging from
as low as RM20 to less than RM 100/month.
This is a considerable saving
which use to incur an average of RM400/month to
operate the diesel genset for only about 5 h
day.
Senior Coastal Engineer
Norzana binti Mohd Anuar
“The catastrophic results of
extreme global flood events continue to
have major damaging effects in both the
developed and the developing world”
e have to live by the consequences of
development for better or for worse. Since
20 to 30 years ago. Malaysia has been
straddled by fast pace development
yearly precipitation between 2000mm and
3000mm, the degree of excess runoff
from developed areas apart from silts coming
from bare land areas are merely too taxful to deal
with.
W
Joint Study of Coastal Flooding at
Golok Rivermouth
Perak’s MB Visit to RPS Kemar
he villagers in RPS Kemar now enjoy 24 hours
electricity supply like the rest of Malaysians. The
average electricity bill per household ranging from
as low as RM20 to less than RM 100/month.
This is a considerable saving to the household
incur an average of RM400/month to
set for only about 5 hours a
“The catastrophic results of
events continue to
have major damaging effects in both the
developed and the developing world”
e have to live by the consequences of
development for better or for worse. Since
20 to 30 years ago. Malaysia has been
straddled by fast pace development projects. With
yearly precipitation between 2000mm and
3000mm, the degree of excess runoff generated
from developed areas apart from silts coming
areas are merely too taxful to deal
This project adds another feather to ACS’s cap
with experience in the first fully operational Solar
Hybrid power project!
Without notice, flash flood occurs in a few
minutes leaving most of the urban dwellers in
awry. These floods occurred mostly
Northeast Monsoon.
In the east coast of Peninsular Malaysia, three
states affected are Pahang, Terengganu and
Kelantan. Sg. Golok, situated in Narathiwat
Province, border between Malaysia and Thailand
flood seasonally in the monsoon. The worst flood
event was recorded on the 21
where Sg. Golok overflows, top up with the
clogging at rivermouth have caused severe
inundation in low lying area especially in Rantau
Panjang.
Joint Study of Coastal Flooding at
Golok Rivermouth
6
Perak’s MB Visit to RPS Kemar
This project adds another feather to ACS’s cap
experience in the first fully operational Solar
Hybrid power project!
Without notice, flash flood occurs in a few
minutes leaving most of the urban dwellers in
awry. These floods occurred mostly during
of Peninsular Malaysia, three
states affected are Pahang, Terengganu and
Kelantan. Sg. Golok, situated in Narathiwat
Province, border between Malaysia and Thailand
flood seasonally in the monsoon. The worst flood
event was recorded on the 21st December 2009
where Sg. Golok overflows, top up with the
clogging at rivermouth have caused severe
inundation in low lying area especially in Rantau
- NEXT STEP -
The repeated events have
instigated
Irrigation and drainage (DID) to come up with a
“Joint Study of Coastal Flooding at Golok
Rivermouth” in collaboration with Thailand
counterpart to mitigate the recurrence events
As an established local Consultant, ACSSB has
been honored to represent the Malaysia team to
carry out an in depth hydrology
on the flood issue, in land and near river mouth
area.
Thailand on the other hand is taking up coastal
erosion study along Narathiwat Province shoreline
until Sg. Kelantan.
The repeated events have
instigated Department of
Irrigation and drainage (DID) to come up with a
“Joint Study of Coastal Flooding at Golok
Rivermouth” in collaboration with Thailand
counterpart to mitigate the recurrence events.
local Consultant, ACSSB has
represent the Malaysia team to
carry out an in depth hydrology / hydraulic study
on the flood issue, in land and near river mouth
Thailand on the other hand is taking up coastal
erosion study along Narathiwat Province shoreline
The study commenced in October 2012 and until
to date several joint meetings with Thailand
counterpart regarding data sharing has been
initiated. Desk study and analysis,
hydrology/hydraulic model setup, calibration
analyses and simulations are all in progress.
Through the same mission of assessing the Coastal
Flood Conditions and to provide concept design
for Coastal Flood Mitigation Measures for Sg
Golok (river) for both sides of the Malaysia
Thailand.
It is in the hope of both countries, Malaysia and
Thailand, that this study could benefit both
regions in the needs and aspirations for current
and future generations.
Su-Ngai Kolok
Rantau Panjang
7
The study commenced in October 2012 and until
to date several joint meetings with Thailand
counterpart regarding data sharing has been
initiated. Desk study and analysis,
hydrology/hydraulic model setup, calibration
analyses and simulations are all in progress.
Through the same mission of assessing the Coastal
Flood Conditions and to provide concept design
for Coastal Flood Mitigation Measures for Sg
Golok (river) for both sides of the Malaysia-
the hope of both countries, Malaysia and
Thailand, that this study could benefit both
regions in the needs and aspirations for current
and future generations.
Rantau Panjang
8
Inlet
Outlet
Access Bridge Pier 1 & Pier 2
Senior Project Engineer
Mustafa Maarof bin Junid
he owner of Sri Jaya iron-ore mining in
Pahang, Phoenix Lake Sdn Bhd engaged ACS
to design a surface storage dam to store
unwanted solid waste from mineral extraction as
well as managing free water. The waste in the
form of slurry will be pumped into the dam from
iron – ore processing plant which is located about