Lukman Alhakim MEng_Project Portfolio

PROJECT

PORTFOLIO

MEng, Mechanical

Engineering (Hons)

Lukman Alhakim Ab Wahid

Lukman Alhakim

Project Portfolio � (M) 013-477 9922 � [email protected]

Page 1 of 34

Table of Contents

Project Engineering ..............................................................................................................2 - 12

1. Automatic Lashing Platform (ALP) ......................................................................................... 2

2. Mitsubishi Heavy Industry (MHI) – Stacking Guide .............................................................. 10

3. Evaluation & Qualification of a New Vendor with Hydraulic Scope of Supply ......................... 11

Mechanical Test .................................................................................................................. 13 - 31

1. Evaluation of New Flipper Design for Rotterdam World Gateway Spreader ............................. 16

2. Provision of Corrosion Evaluation for Rotterdam World Gateway

(RWG) Spreader – Post Commissioning................................................................................. 17

3. Evaluation of Photovoltaic Sensors Under Harsh Environmental

Conditions – ALP Component Testing ................................................................................... 18

4. Provision of Design & Fabrication of RWG Mechanical Test Jig

& Conceptual Verification of Spreader Unit ........................................................................... 20

5. Corrosion Evaluation of Metric Precision Steel Pipes

for Vendor Comparative Assessment ..................................................................................... 21

6. Evaluation of Anti-Rust Compound for Product

Comparative Assessment – Dinitrol & Techtyl ....................................................................... 23

7. Evaluation of Oil Level & Temperature Indicator for Vendor

Comparative Assessment – IFM & Hemomatik ...................................................................... 24

8. Evaluation of Oil Heater for Vendor Comparative Assessment EVT & AVAK ........................ 25

9. Evaluation of Hydraulic Hoses & Clamps for Suitable Pairing Selection .................................. 26

10. Performance Evaluation of Non-Metallic Dampers – A Comparative Assessment ..................... 27

11. Evaluation of Sheave Wheels for Vendor Comparative Assessment ......................................... 28

12. Provision of Functional Test for Guide Block & Twistlock Arm

for Vendor Comparative Assessment ..................................................................................... 29

13. Provision of Functional Test for Hydraulic Leakage Verification on Hose Assemblies .............. 30

14. Provision of Functional Test for Hydraulic Leakage Verification

on RWG Valves & Manifold Blocks ...................................................................................... 31

Marine Machinery Design - Spreaders............................................................................... 32 – 34

1. Local ................................................................................................................................... 34

2. International ......................................................................................................................... 34

Lukman Alhakim


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Project Engineering

Apr 13 – Mar 15

“Bridges the boundaries between engineering and

project management”

Lukman Alhakim


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Automatic Lashing Platform (ALP) Apr 13 - Mar 15 (24 months)

Project Description:

ALP (red machine on the ground) is the solution for automated handling of twistlocks1 within

shipping terminals. Located under the gantry cranes this device increases operational efficiency by

reducing the load/unload cycle time & promotes safety by eliminating human labour.

It is self-sufficient via means of converting potential energy from the weight of containers into

pressurised hydraulic & pneumatic power. Stored within linear actuators & accumulators the energy

will then be gradually released to serve its fundamental & auxiliary functions.

Engineering

Standard

Skill Segment

EN 15056, ISO 2553, ISO 13920, ISO 2768, ISO 1302, EN 13849-1,

EN 13681, EN 1005, EN 547-2, EN 547-3, , ISO 17165-2, 2006/42/EC,

1997/23/EC, ASME B16.5 & ASME B31.3 & NACE

Project Planning, Sheet Metal, Welding, Hydraulic System, Hydraulic

Fluid Power, Ergonomics, Process Piping, European Directives (CE),

Corrosion Study, AutoCAD 2D2, Autodesk Inventor 3D

3, Jig Design,

Testing, Technical Report, & Vendor Management

Challenges Language barrier & work-flow culture

Lesson Learnt Fluidity of information between testing & design team will propel

progress & boost productivity

1 A twistlock and corner casting together form a standardised rotating connector for securing shipping containers 2 Generally utilized for hydraulic schematic & P&ID designs 3 Structural design & finite element analysis (FEA) of the overall machine as well as its critical sub-components (i.e. load bearing sections, pick – points segments). In addition the dynamic characteristic of non-metallic components such as rubber

dampers and hydraulic fluid actuators were being simulated via internal solver within Autodesk Inventor software

Lukman Alhakim


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Scope of work:

1. Design

� Basic Engineering Design (BED)

Site Survey& Prototype Documentation

o Design data acquisition – The established prototype unit created in Böel, Germany

were being scrutinised for details of pipe routings, component allocation &

fundamental system understanding4

o Subsequent visits were utilized for design verification & endorsement of previous

engineering solutions as well as creating new design entry for impromptu fixes

o Each documentation period were segregated into three (3) different phases;

• Initial – Documentation of new technology implemented onto the existing

prototype unit

• Intermediate – Reflection of previous way forward, discussion on solution

costing & relevant alternative approach

• Final – Product development planning for future deliveries; mechanical &

hydraulic design. Components localization for procurement leverage

Fundamental Pipe Modelling

4 Only apply to the first site visit where product owner describe in detail of ALP’s fundamental working principal in detail in

the scope of mechanical, hydraulics, electrical & control system

1 2

Figure 1: 1 - Fundamental pipe routing, 2 – A pipe sub-drawing with dimensions

Lukman Alhakim


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Fundamental Pipe Modelling (continued)

o Drafting of 3D pipe routing as outline for detail design stage were perfected in

multiple phases. Section of interest are trolley, bottom frame & upper frame

o Preliminary optimization in the scope of component reduction and introduction of

continual pipe routing which promotes higher flow efficiency

o Improvements updates on hydraulic P&ID that covers the energy, lifting, trolley &

manipulator system; in-sync with development planning

Conceptual Proposal

o Feasibility studies and engineering concepts were put into action to address ongoing

issues & future optimization in the scope of:

• Safety

Focusing on design of safety signs depicting potential hazardous

complication as well as implementation of physical counter measures e.g.

anti-slip floorings.

• Ergonomics

Design modification that advocate ergonomic considerations as stipulated in

ISO 13861, EN 614-1 & 2 as well as CEN guide 414. Personnel access

into/out from machine, lighting intensity & duration of working in abnormal

posture were some of the design examples with ergonomics due diligence.

• Certification

As European terminals will be amongst the prospectus clients to market this

machine, compliance to the European Directive is paramount. Fundamental

requirements as per stipulated in 97/23/EC & 2006/42/EC were implemented

especially in the scope of machinery process, safety & pressure equipment.

Figure 2 - Conceptual optimization sketches drawn during a site survey

Lukman Alhakim


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• Cost Reduction

Selection & approval of engineering components with due diligence. This is

achieved via practicing accurate material & steel profile selection and other

purchase components; avoiding over specifications. Working hand in hand

with procurement in outsourcing components with premium price tag.

• Function Optimization

Improvements were segregated into multiple-phases; the initial stage tackles

fundamental issues via brainstorming conceptual ideas across multi-

disciplinary division. Locus of development is the energy system where

boosting the hydraulic efficiency is paramount in achieving a self-sufficient

setup.

� Detail Engineering (DE)

Engineering Drawings

Provision of preparing detail engineering drawings5 for in-house fabrication process &

production reference during assembly stage. The following are the type of drawings

produced for this project:

o Component drawings o Hydraulic Schematics

o General Assembly (GA) o Hydraulic P&ID

o Bill of Materials (BOM) o Pipe Assemblies

5 Compliance to EN 15056, ISO 2553, ISO 13920, ISO 2768, & ISO 1302

1

2

3

4

Figure 3: 1& 2 - Pipe assemblies modelling, 3 - Hydraulic P&ID, 4 – A sample of pipe drawing

Lukman Alhakim


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Operation Manual

ALP operation manual was compiled in a continuous & chronological manner from detail

design & until testing phase. In the scope of mechanical & piping, information related to

hydraulic functionality, detail description of sub-system & components were allocated

into respective chapters. Supplementary visual aids were provided in the form of

commercialized perspective drawings.

2. Trainer

Conducted an introductory product data management (PDM)6 training for ALP technical team

in Böel, Germany on October 2013. Supplemental coaching was also provided on the

Autodesk Inventor 3D - the project primary designing tool.

6 Autodesk Vault 2013 was the PDM system utilized at that time

Figure 4 - Visual aids for manual compilation; samples depicting various greasing points

Lukman Alhakim


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3. Testing

� In-house testing

The conceptual verification of new engineering designs was awarded to local engineering

team in Malaysia. Provision of test procedures, methodology and resource management

were brought up during technical meetings for multi-disciplinary discussion prior to

commencement of any test activities.

Scope of work includes:

o Project Planning – Time scheduling & resource management (human & capital)

o BED – Basic fixture design that able to deliver comparative results from actual

operating conditions. Working closely with sourcing, vendors & fabricators to

achieve fixture design that are reliable, cost efficient and specifications

compliance

o Execution – Initial setup, performing test and data acquisition

o Documentation – Technical report compilation with quantifiable end-results

leading to relevant recommendation on the tested system/components

2

1

Figure 5: 1 - Sensor evaluation setup, 2 - Assessment on manipulator lifting cylinder

Lukman Alhakim


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� Field Test

Engaged in multiple field testing in Southampton & Hamburg shipping terminals.

Primary task involves hydraulic data acquisition, fault findings & documentation. These

discoveries will then be analysed and added into the active development list.

Achievements: ✔ Laid groundwork on the 3D piping layout for ALP production unit ✔ Achieved 15% (RM 195,000+) cost7 reduction from continuous collaborative effort

with sourcing team in the field of:

� Component harmonisation - Control valves & retaining clamps

� Localization of hydraulic pipes & auxiliary connectors

� Breaking down costly packages into individual components ✔ Post PDM training session, respective engineers were able to independently monitor

design updates remotely; boosting team productivity

Recommendations:

7 In reference to direct cost from mechanical components purchase i.e. pipes, hydraulic hoses, actuators and auxiliary valves

Lukman Alhakim


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Provision of Detail Engineering of Hydraulic Schematics Feb – Mar 14 (1 month)

for Mitsubishi Heavy Industries (MHI) – Stacking Guide


Spearheaded hydraulic design integration between client’s hydraulic functions and the standard yard

spreader; enabling value adding features of side stacking & supplementary pump-failure prevention.

A time critical collaborative project with immense business potential for repeat orders.

Engineering Standard

Skill Segment

EN 15056, ISO 2553, ISO 13920, ISO 2768 & ISO 1302

Hydraulic System, AutoCAD 2D, Autodesk Inventor 3D

Challenges Client’s reference drawings released in stages

Lesson Learnt Communication ought to be made to end-user directly

without an intermediate entity (commercial personnel)

Scope of work:

1. BED & DE

� Conceptual and cross reference study based on client’s hydraulic P&ID

� Integration proposal according to production’s common components8

� Detail design which consist of general assembly (GA), hydraulic P&ID & preparation of

bill of material (BOM)

2. Procurement

� Outsourcing & localization of special valves for cost reduction purposes

Achievements:

The project was successfully offered to client two weeks prior to due date with an additional 13% cost

savings

8 Consisting of hydraulic control valves, connecting lines & instrumentation components

Lukman Alhakim


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Evaluation & Qualification of a New Vendor with Hydraulic Scope of Supply (6 months)


Due to the new management policy9 an existing vendor for hydraulic services were to end their

contract of supply. The scope of evaluation for the new replacement shall cover the following

province:

1. Internal processes & system evaluation

2. Product features & product process assessment

Engineering

Standard

Skill Segment

DIN 3015, ISO 17165-1, ISO 6606, ISO 14993 &

ISO 10289

Vendor Qualification, Hydraulic Fluid Power, NDT

& Technical Report

Challenges A dynamic & thorough assessment program

9 A more stringent approach in dealing with underperforming vendors

Figure 6 - Supplier's warehouse & test facilities

Lukman Alhakim


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Scope of work:

1. Site Visit

� To verify vendor’s facility is within satisfactory operational conditions

� Reviewing safety aspects of the facility & their provision for personnel protective

equipment (PPE)

� Assessment on measurement techniques, calibration programmes & testing schemes

� Reviewing internal document control & process flow

2. Testing

� Evaluation of component10

covering the following scope:

o Material specification – DIN 3015

o Labelling – ISO 17165-1

o Performance – ISO 6606, ISO 14993 & ISO 10289

o Dimensions – Physical dimension vs. technical drawings

3. Documentation

� Site visit evaluation report – An independent review

� Technical report to include rejection/approval of individual component tested

Outcome:

Approval of the new supplier with due diligence; ongoing monitoring & evaluation especially in the

realm of dimensional control (for DIN 3015 clamps) as well as hoses labelling (as per depicted in ISO

17165‐1 - Appendix 7.2)

10 Consisting of hydraulic hose assemblies, DIN 3015 rated clamps & auxiliary supplied loose connectors

Lukman Alhakim


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Mechanical Testing

Jan 12 – Aug 13

“Determination of mechanical properties and

behaviour of material, structures and machines”

Lukman Alhakim


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Figure 7 – Test Flow Chart

Project Segregation:

Projects were segregated by their requestor/owners as shown in diagram below:

Figure 8 – Chart Depicting Test Ownership

Achievements: ✔ PDM database administrator for Test Centre department - Mechanical jigs ✔ Rectified 520 errors in PDM system - Saved RM10k in IT consultancy fees ✔ Introduced & standardized technical report template for Test Department ✔ A department backbone - Lead to achieve 1/3 of its KPI for 2H FY 2012 ✔ Centralization of in house power-pack11

units – BED for budgetary approval ✔ Spearheaded design & material selection for Rotterdam World Gateway jig ✔ Entirely responsible for revising 2D jigs design into 3D CAD models

11 Hydraulic pump sets that can cater up to 250 bar of hydraulic fluid pressure

Test Owners

Sourcing, R&D, QA &

Engineering

Department

Feasibility Stdy.

Facilities

Budgetary,

Man power,

& Schedule

Testing

Planning,

BED, FEED,

Jig Fabrication

& Execution

Deliverables

Tech. Report with

Unprejudiced

Recommendation

Revise or 3rd party

Owners/

Requestor

R&D

(Sweden &

Germany)

Customer

Engineering

Sourcing

Department

Quality

Assurance

Lukman Alhakim


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Recommendations:

Lukman Alhakim


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Evaluation of New Flipper Design for Rotterdam World Gateway

Spreader (3 months)


Mechanical flippers are an essential part of a crane spreader. It provides guidance to align the

spreader’s twistlocks into container’s corner castings during pickup sequence. For this particular

project, a hybrid design was explored where the normal practice of vertical open/close motion were

replaced with a horizontal swing motion. Parameters related to the efficiency of this new design were

tested before commencing to mass production phase.

Engineering

Standard

Skill Segment

EN 15056, ISO 2553, ISO 13920, ISO 2768, ISO 1302, EN 1005, EN 547-2,

EN 547-3, ISO 4406, ISO 17165-2

Project Planning, Hydraulic System, Jig Design, Testing & Technical Report

Challenges Noble jig design & resource limitations

Scope of work:

1. BED

� Conceptual study &planning of Mechanical Test to allow the following parameters to be

evaluated:

o Locking motion fluidity – To achieve a seamless angular opening & closing by

understanding the relation between location of linear actuator with respect to the

flipper and its structural frame

o Hydraulic hose sizing – To control the swing speed of opening & closing within

the working time frame as dictated within internal standard. Alternative

introduction of reducing connectors to be explored to promote hose sizing

standardization – procurement leverage

o Impact assessment – Noise & vibration data analysis due metal to metal contact

during operation

2. Procurement Support

� Working closely with vendors and sourcing team to achieve test setup that are technically

verified, reliable & cost effective

3. Testing & Documentation

� Initial fixture setup & component assembly

� Data acquisition with the aid of noise & vibration logger

� Technical report to include approval/rejection of the new design

Outcome:

1. Introduction of reducing connectors for precise motion & speed control

2. Proposal to fine tuning the software algorithm to control the motion sequence - reducing

impact sound emission

Lukman Alhakim


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Provision of Corrosion for Rotterdam World Gateway Spreader

- Post Commissioning (4 months)


A Quality Service Report (QSR) related to corrosion of RWG spreader occurring in Port of

Rotterdam, Netherland was issued by the in-charged service engineer. This has raised concerned from

top management since it was taken placed in one of the busiest terminal in Europe; global reputation

were as stake. Considering past spreaders were in good working condition with acceptable corrosion

allowance, this project shall investigate the root cause of such an abnormal circumstances.

Areas which were severely affected by corrosion:

1. Hydraulic linear actuator – piston unit

2. Retainer plate for load bearing shaft

3. Exposed components prone to regular use – e.g. ladder steps & walkways

Engineering

Standard

Skill Segment

ISO 9227, ISO 14993, ISO 2081, ISO 10289 & NACE

Project Planning, Corrosion Study, Testing & Technical Report

Challenges Reference were limited to photos taken by service personnel

Scope of work:

1. BED

� Conceptual study, planning & execution of Environmental Test to allow the following

parameters to be evaluated:

o Corrosion resistance – Evaluation of respective components under in-house salt

spray test in accordance with ISO 14993

o Mounting orientation & location – Comparative evaluation on corrosion rate

o External factors – Environmental acidity & abrasive wind borne particles


� Physical & visual inspection of coating performance as per dictated in ISO 10289

� Technical report to recommend relevant counter measures to curb future rust initiation

Outcome:

1. Based on the spreader’s service condition12

a higher electroplated coating thickness were

suggested - from 12 to 25 micron

2. Introduction of anti-rust coating on unpainted steel structure surfaces & hydraulic connectors

3. Other components with low dimensional tolerance to be coated with hot dipped galvanization

12 Corresponding to outdoor service class in severe corrosive conditions e.g. marine or industrial (ISO 2081)

Lukman Alhakim


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Evaluation of Photovoltaic Sensors Under Harsh Environmental

Conditions – ALP Component Testing (3 months)


One of the fundamental functions of the ALP machine is to be able to detect the presence/absence of

twistlock via special tool13

. A photovoltaic sensor is cardinal to accomplish this function. However

due to the exposed nature of a marine working condition14

, common issues such as intermittent loss of

sensor signal will need to be addressed for continuity of machinery operation.

The aim is to verify the presence of any of the following failure modes:

1. Signal loss – Under pre-defined conditions with variation in temperature, illumination state &

reflector surface conditions

2. Alignment w.r.t reflector - Due to sensor’s finite field of sensing


Skill Segment

EN 15056, ISO 2553, ISO 13920, ISO 2768 & ISO 1302

Sheet Metal, Testing, AutoCAD 2D, Autodesk Inventor 3D &

Technical Report

Challenges Simulation of harsh marine conditions within in-house test facility

13 A patented tool that serve the function of locking/unlocking of twistlock to & from container’s corner casting. It is

operated by means of rotary hydraulic actuators 14 Typical weathering conditions such as heavy rainfall, snowing & ice flakes. Other external contributing factors for

instance accumulation of dirt & oil from prolonged operation period.

1 2

3 4

Figure 9 : 1&2 - Test fixture to evaluate environmental conditions, 3 - Fixture for alignment assessment,

4 - The actual sensor used on the prototype unit

Lukman Alhakim


Page 19 of 34

Scope of work:

1. BED

� Conceptual study, planning & execution of Mechanical Test to allow the following


o Different weathering elements

o Sensor orientation & angular tilt of the sensor w.r.t its reflector (twistlock)

o Distance limitation w.r.t its reflector (twistlock)

o Fitness-for-purpose evaluation on the weather enclosure design

� Working closely with German team to achieve a test setup that is capable of reproducing

the actual operating conditions

2. Testing

� Initial fixture setup & component assembly

� Scheduled planning for test technician to run & exquisite relevant test data

3. Documentation

� Technical report to include approval/rejection of the tested sensor & its enclosure

Outcome:

1. Recommendation on sensor’s optimum operating range & angular tilt

2. Verification of the present weather protection enclosure – A cost effective solution with ease

of visual monitoring, maintenance access & impervious to majority of the tested elements

Lukman Alhakim


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Provision of Design & Fabrication of RWG Mechanical Test Jig

& Conceptual Verification of Spreader Unit (4 months)


A new and anticipated spreader line equipped with angular tilting features were to be tested within

production facility. This project focuses on:

1. The design of its testing fixture

2. Conceptual verification test of the new angular tilting features

Engineering

Standard

Skill Segment

EN 15056, ISO 2553, ISO 13920, ISO 2768, ISO 1302, EN 1005, EN 547-

2, EN 547-3, ISO 4406, ISO 17165-2

Project planning, Sheet Metal, Welding, Hydraulic Fluid Power, FEA,

Autodesk Inventor 3D & Technical Report

Challenges Cost driven, time constraint & achieving precision a large steel structure

Scope of work:

1. BED & DE

� Project planning from basic engineering phase to delivery into production facility

� Raw materials & fabrication costing, resource allocation, logistics & assembly procedures

� Conceptual design of the test fixture in reference to test parameters & structural limitation

� Detail design which consist of general assembly (GA) & components drawings,

preparation of bill of material (BOM) for fabricators

2. Procurement & Vendor Management

� Localization of raw materials for cost reduction process – Refraining from profiled steel

� Proactively working with external fabricators to ensure design tolerance were achieved

3. Testing

� Planning & execution of Mechanical & Hydraulic Tests on the spreader unit

� Collaboration with QC Department for initial fixture setup, assembly & commissioning

� Data acquisition with Hydac HMG 3010 data logger – pressure, temperature & flow rate

4. Documentation

� Compilation of technical manual, safety operating procedures & maintenance15

scheme

� Technical report to include approval/rejection of individual features of the new spreader

Achievements: ✔ Received recognition from local QC & R&D Sweden post-test fixture commissioning due to its

low cost and on-time project delivery

15 Focuses made on areas prone to abrasion where greasing procedures & intervals were proposed

Lukman Alhakim


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Corrosion Evaluation of Metric Precision Steel Pipes for Vendor

Comparative Assessment (3 months)


Several hydraulic pipes within a prototype machine have been discovered to portray internal

rusting characteristic. Further root‐cause study has exposed an oversight by the supplier

whereby these inner pipes were unprotected via oil‐flushing before shipment. Exposure to

high salinity and humid conditions during sea‐freight has degraded pipes inner surfaces

where passivation protection was not applied.

The sole aim for this test is to get a progressive overview of pipe samples from two (2)

different vendors & their response to salty16

environment.

Engineering

Standard

Skill Segment



Challenges Reproducing marine environment within an in-house test facility

Scope of work:

1. BED

� Conceptual study, planning & execution of Environmental Test to allow the following


o Corrosion resistance – In-house salt spray test in accordance with ISO 14993

o Mounting orientation & location – Comparative evaluation on corrosion rate

16 The salt solution used is with 50g/l ±5g/l composition as stipulated in ISO14993 (solution preparation ONLY).

1

2

4

3

Figure 10: 1 - Dimensional verification, 2&3 - Comparison on corrosion outlook between two

suppliers, 4 - Salt spray test setup

Lukman Alhakim


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� Initial sample tagging & test fixture erection

� Supplementary assessment – Visual aesthetics, deburring quality & dimensional

verification

� Physical & visual inspection of coating performance as per dictated in ISO 10289

3. Documentation

� Technical report to recommend relevant counter measures to curb future rust initiation

Outcome:

1. Comparative assessment provides firm evidence in which a complete coating (inner & outer)

prevail with lower oxidation characteristics (rust distribution & class rating).

2. To avoid reoccurring predicament only this type of coating should be used on prototype

piping for hydraulic distribution lines

Lukman Alhakim


Page 23 of 34

Evaluation of Anti-Rust Compound for Product Comparative

Assessment – Dinitrol & Techtyl (3 months)

_


Anti‐rust compound is being widely used in Bromma’s production facility to curb rust initiation on

unpainted steel surfaces and hydraulic connectors. A cost driven project to outsource & substitute the

current compound with an alternative option.

Engineering

Standard

Skill Segment



Challenges A dynamic & thorough assessment program

Scope of work:


� Planning & execution of:

o Visual & Physical Inspection – Features such as compound clarity, opaqueness

& tackiness upon touching are visually & physically inspected

o Compound Removability – Supplementary test to measure removability of each

compound when subjected to a common industrial solvent

o In-House Salt Spray - To accelerate the rusting process salt mist17

were sprayed

on a twice/day basis

� Collaboration with SIRIM for 240 hours of accelerated salt spray exposure

� Technical report to propose rejection/approval of the new anti-rust compound tested

Outcome:

Both in-house & external assessment converged towards an outcome; Dinitrol outperforms its

counterpart when it comes to protecting components against further rust propagation

17 The salt solution used is with 50g/l ±5g/l composition which adhered to ISO 14993 (solution preparation ONLY).

1 2

3

Figure 11: 1 - Test samples after tagging, 2 - Compound residual post application, 3 - End result for

after salt spray test

Lukman Alhakim


Page 24 of 34

Evaluation of Oil Level & Temperature Indicator for Vendor

Comparative Assessment – IFM & Hemomatik (2 months)

_


LT8022 is an electronic level and temperature sensor by IFM supplier whereby its performance

characteristics to be tested against the pre-existing Hemomatik brand. Temperature range, liquid level

reading and drop test to be performed in-house. Delegation of vibration & shock response certification

to SIRIM.


Skill Segment

EN 60068-2-27-Ea & EN 600068-2-6-Fc

Autodesk Inventor 3D & Technical Report

Challenges Overall comparative assessment

Scope of work:



o Simulation Test – Subjection to 3D simulation & physical predictive

experimentation to understand constraint, fitting tolerance & micro-interference

with other components

o Functional Test – Comparison on reading precision & accuracy

o Drop Test - To match realistic spreader operating condition during container

loading/unloading

� Collaboration with SIRIM for the following verification:

o Sinusoidal Vibration - Adhered to EN 600068-2-6-Fc

o Shock Response - Adhered to EN 60068-2-27-Ea

� Technical report to include approval/rejection of tested components

Outcome:

Rejection of the new product for production use as it fell short in majority of the critical merits

1

1

Figure 12: 1 - 3D simulation showing micro-interference, 2 - Performance evaluation post external

SIRIM test

Lukman Alhakim


Page 25 of 34

Evaluation of Oil Heater for Vendor Comparative Assessment

EVT & AVAK (1 month)

_


In brief an immersion heater is used as a direct contact heating method of oil within reservoir. AVAK-

11357 is an immersion heater from AVAK whereby its performance characteristics will be tested

against pre-existing EVT brand.

Skill Segment Autodesk Inventor 3D, NDT & Technical Report

Challenges Overall comparative assessment

Scope of work:

1. Testing


o Simulation Test – Subjection to 3D simulation & physical predictive

experimentation to understand constraint, fitting tolerance & micro-interference

with other components

2. Documentation

� Technical report to include approval/rejection of the new component

Outcome:

Rejection of new product due its dimensional non-compliance with spreader reservoir design

1

3

2

4

Figure 13: 1&2 - 3D simulation depicting possible interference, 3 - One to one visual comparisons,

4 - Dimensional checking procedure

Lukman Alhakim


Page 26 of 34

Evaluation of Hydraulic Hoses & Clamps for Suitable

Pairing Selection (2 months)

_


In general a clamp kit is used to ensure a tight hold on the hydraulic hose as well as providing

mechanical mating between hose and the spreader's body. It is also used to absorb shock and vibration

caused by fluid surges within pipes, tubes and hoses in both mobile and stationary applications.


Skill Segment

DIN 3015

Dimensional Measurement & Technical Report

Challenges Resource planning for testing on spreader

Scope of work:

1. Testing


o Physical Fitting & Mounting – To observe mating characteristics of each clamp

against their respective hoses on the spreader

o Functional Test – Mating characteristics when hoses were pressurized under

operating pressure

2. Documentation

� Technical report to include approval/rejection of each hose-clamp combinations

Outcome:

Recommendation to revise of a number of hose-clamp pairs due to unsatisfactory clamping attribute

1

2

3

Figure 14: 1 – The elementary constituents of a DIN 3015 clamp, 2 - Range of clamps to be tested, 3 – Fitting test onto a production spreader

Lukman Alhakim


Page 27 of 34

Performance Evaluation of Non-Metallic Dampers

- A Comparative Assessment (18 months)


Bromma’s Spreaders are equipped with landing buffer attached between the main frame and

the telescopic beam unit (TBU). It served as shock absorbers between the telescopic beam &

the main beam; dampening excessive collision during operation.

For any landing buffer test, the passing upper limit shall be 75,000 cyclic loads under 12T

pressure. The sample shall NOT have any resin detachment nor do any major disfigurements

that will affect its dampening function.

Skill Segment Project Planning, Fatigue Testing & Technical Report

Challenges Prolonged fatigue test duration, continuous assessment,

test bench failure due to fatigue

Scope of work:

1. Testing

� Conceptual study, planning & execution of Fatigue Test

� The scope of evaluation shall cover the following province:

o Fatigue life evaluation under continuous cyclic loading

o Static & dynamic understanding of the material under lubricated conditions

� Physical & visual inspection of rubber & resin performance

2. Documentation

� Technical report to include approval/rejection of each samples

Outcome:

All samples were showing a wide performance variation & similar resin detachment modes. Only

certain natural rubber buffer samples exceeded the required approval threshold of 75,000 cycles

1

2

3

Figure 15: 1 - Buffer sample with applied grease, 2 - Hydraulic press fixture, 3 – A failure mode showing resin detachment

Lukman Alhakim


Page 28 of 34

Evaluation of Sheave Wheels for Vendor Comparative Assessment

(1 month)


In essence a sheave wheel works in the same principle as a mechanical pulley. In spreader

operation it is utilized to regulate wire ropes that hold a spreader to its respective crane. For

this test, four sheave wheel units from a new supplier will be evaluated against the pre-

existing brand; an indirect process for procurement leverage.


Skill Segment

ISO 5817 & ISO 6520-1

CMM, Welding Defects, Fatigue Test & Technical Report

Challenges Non Destructive Test (NDT) limited to visual assessment

Scope of work:



o Functional test – Collaboration with SIRIM to utilize an equipped facility

o Dimensional Verification – with the aid of a coordinate measurement machine

o Visual comparison – Detection of welding imperfection (ISO 6520-1)

� Technical report to include approval/rejection of the tested components

Outcome:

Rejection of new samples due to unsatisfactory dimensional tolerance & fabrication

1

2

3

Figure 16: 1 - Relative location of sheave wheel w.r.t spreader & crane,

2 – A Draft sketch depicting fatigue test setup, 3 – Test samples

Lukman Alhakim


Page 29 of 34

Provision of Functional Test for Guide Block & Twistlock Arm

for Vendor Comparative Assessment (1/2 months)


A request for a functional test on a number of guide blocks & twistlock arms by IQC department.

The goals are as follows:

1. Detection of visible defects on samples characterize by the typical deformities18

2. Verifying welding joins are absence from defects that could shorten life cycles

3. Retrieving relevant dimensions from samples via coordinate measurement machine (CMM) &

cross‐checking with respective component drawings

Engineering

Standard

Skill Segment

ISO 5817 & ISO 6520-1

CMM, Welding Defects, Fatigue Test & Technical Report

Challenges Non Destructive Test (NDT) limited to visual assessment

Scope of work:

1. Testing


o Dimensional verification – With the aid of a coordinate measurement machine

o Functional Test – in house test fitness for purpose

o Field Test – On selected samples under actual operating conditions

� Visual comparison & detection of welding imperfection coherent with ISO 6520-1

2. Documentation

� Technical report to include approval/rejection of the tested components

Outcome:

Rejection of new samples due to unsatisfactory welding characteristics; imperfection in:

1. Incorrect weld toe – Imperfection ISO 6520-1 (505)

2. Excessive asymmetry – Imperfection ISO 6520-1 (512)

3. Insufficient throat thickness - Imperfection ISO 6520-1 (5213)

18 Corresponding to scratches, dings and unusual marks on the metal surface

Lukman Alhakim


Page 30 of 34

Provision of Functional Test for Hydraulic Leakage Verification

on Hose Assemblies- (1/2 months)


A request for a functional test on hydraulic hoses foreseen to be faulty was issued by IQC department.

The aims of this test are as follows:

1. Detection of visible defects on hoses characterize by the typical deformities such as stretched

marks, abrasion on rubber & dings inside metal connectors

2. Verifying hoses are in usable state via pressurizing to their allowable rated pressure

Engineering

Standard

Skill Segment

ISO 6606, ISO 13184 (Pressure Decay Technique - EN 1779)

& ISO 17165-2 (Appendix A.1)

Hydraulic Fluid Power & Technical Report

Challenges Resource limitation19

Scope of work:

1. Testing

� Resource coordination & initial assembly setup

� Planning & execution of Pressure Decay Test – According to EN 1779

2. Documentation

� Technical report to include approval/rejection of the tested samples

Outcome:

Approval of samples for production use due to satisfactory pressure retention

19 At the time of this test, all usable hydraulic pump sets were occupied with dedicated test. An alternative way forward was

to scavenge & repair a faulty pump from an obsolete spreader unit.

Lukman Alhakim


Page 31 of 34

Provision of Functional Test for Hydraulic Leakage Verification on

RWG Valves & Manifold Blocks (1/2 months)


A request for a functional test on valves & manifold blocks foreseen to be faulty was issued by IQC

department. The aims of this test is to verify the components are in usable state via pressurizing to

their allowable rated pressure.


Skill Segment

ISO 13184 (Pressure Decay Technique - EN 1779)

Hydraulic Fluid Power & Technical Report

Challenges Root cause analysis & failure mode detection

Scope of work:

1. Testing

� Resource coordination & initial assembly setup

� Planning & execution of Pressure Decay Test – According to EN 1779

2. Documentation

� Technical report to include approval/rejection of tested samples

Outcome:

Approval of samples for production use due to satisfactory pressure retention

Lukman Alhakim


Page 32 of 34

Marine Machinery Design - Spreader

Aug 10 – July 12

“Devising mechanical machinery designs,

for shipping terminal needs”

Lukman Alhakim


Page 33 of 34


A spreader (red machine in above picture) is a device used for lifting containers and unitized cargo. It

is commonly used for containers that have a locking mechanism at each corner castings. A spreader

can be used on a container crane, a straddle carrier and with any other machinery to lift containers.

Engineering

standard

Skill Segment

EN 15056, ISO 2553, ISO 13920, ISO 2768, ISO 1302, DIN 3015,

ISO 17165-2, ISO 4406

Sheet Metal Design, Welding, Hydraulic Fluid Power, Project

Management, AutoCAD 2D, Autodesk Inventor 3D

Challenges Multiple project coordination, last minute technical amendments by

clients

Scope of work:

1. BED & DE

� Conceptual and cross reference study based on client’s hydraulic P&ID, headblock20

dimensions, critical component request & painting specifications

� Detail design which leading to preparation of

o General assembly (GA) drawings – Specifying painting requirements, safety

decals & critical parameter notations to aid quality control checking

o Hydraulic schematics – Depicting location of pump, flow dividers, control valves

and other auxiliary components which are fundamental to a spreader operation

o Bill of material (BOM) – For procurement & planning during initial stage of

design. A production check-list during assembly of the spreader unit

2. Procurement Support

� Providing technical steer to sourcing in terms of special components with long lead time

– mechanical & hydraulic items

3. Documentation

� Operational manuals co-ordination between technical writer and sales-force

20 A load bearing mechanical device that act as an intermediate in pairing both quay crane & spreader

Lukman Alhakim


Page 34 of 34

Project List:

1. Local - Malaysia

� ZPMC - Westport, Malaysia – Twin ship to shore

2. International

� Barbados Port Inc. : Single ship to shore spreader

� APM Terminal, Mexico : Twin electric-yard spreader

� DP World - Caucedo, Spain : Single ship to shore spreader

� Suez Canal Container Terminal, Egypt : Twin yard spreader

� ZPMC - Lazaro Cardenas, Mexico : Twin electric-yard spreader

� PSA - Sical Terminal, India - In charge of designing hydraulic system

� ZPMC - WWI, India : Twin electric-yard spreader with new hoisting section

� Terminal de Contentores de Leixoes , Portugal: Twin ship to shore spreader

� Konecranes - Nutep, Russia : Single yard spreader with cold climate structure

� ZPMC - Nansha II, China : Twin ship to shore spreader with new hoisting section

� ZPMC - TESCA, Columbia : Twin electric-yard spreader with new hoisting section

� Gazal Logistics - Umm Qasr, Iraq : Single yard spreader with new hoisting section

� Port of New Orleans, USA : Twin ship to shore spreader with new hoisting section design

� Kocks Krane GmbH - ITC Terminal, Vietnam : Single yard spreader with impact

protection

� Libherr - Petrolesport, Russia : Single ship to shore spreader with ergonomic ladder

design

� SANNY Group Co. - TCDD Izmir Turkey Twin electric-yard spreader with new hoisting

section

� Mitsui - Exolgan, Argentina : Twin electric-yard spreader with ergonomic access holes &

handrail

� Konecranes - Port of Klaipeda, Lithuania : Twin electric-yard spreader with cold climate

structure

Achievements: ✔ Laid groundwork of the 1st hydraulic-headblock order - hydraulic schematics ✔ Design-revamped an existing sensor technology into 2nd generation spreaders

Recommendations:

Lukman Alhakim MEng_Project Portfolio

Career

evaluation qualification

evaluation of oil heater

evaluation of sheave

new vendor

provision of functional

hydraulic leakage verification

hydraulic scope of supply

project portfolio meng