IEM PI Section A – Awareness of Engineering sustainability, health and safety issues-1

(For PI section A, candidate will have to write an essay, which the question was earlier prepared by interviewers based on candidate’s Report on Training and Practical Experience. The following were predicted questions, by Mr. BAY based on his submitted report to principal interview and his trial exercise prior to sitting of PI.)

Awareness of engineering sustainability, health and safety issues Related Question

What are the possible hazards at oil & gas plant? What are the safety precautions that engineers and other staff need to uphold?

What are the safe work practice, permit and procedure to work at oil and gas inplant area?

Introduction:

Engineers are inevitably needed and present at site. Though engineers are not involving themselves in the physical works like other construction staffs, they shall also aware of danger and hazards that may fall upon them. Therefore, they are also need to take safety precaution.

For special industries such oil & gas industries, there are special hazard too. As the industry is to deal with oil and gas, it is understand that the special hazards are gas leaking which may cause explosion. All staffs working at oil and gas facilities shall adhere to strict regulation of what not to do in the compound.

Danger and hazards from special industries such as oil and gas project:

Gas leaking:

Gas leaking can cause explosion if there is inappropriate human behavior such as smoking. It is often too, if need to capture photo, only special camera without flash are permitted.

Engineers and all staffs shall adhere to prohibited behavior and always be calm when executing their duties at site. It is important for them to identify possible alert and sign of danger. Apart of working on their respective duties, they shall check the gas detector for gas leaking prior to and after work.

Hot items and steam:

The pipes are subjected to either internal hydrostatic or gas pressure which is extremely hot. To mitigate/ alleviate high locked-in forces, the hot steam is released at certain locations. Engineers and other staffs shall be aware and alert of these matters so that they don’t get hurt, harm and burned skin.  

Chemical leaking:

There will be also stocks of chemical materials, which are highly toxic at the industry compound. They shall handle with care.

Working at height:

Working at oil and gas facilities compound, there will be routine walking and inspection the inplant compound. It is sometime that engineers need to walk up the cylinder silos of 10-storey high.

Safety precaution/ safe work practice, permit and procedure:

Safety induction course:

Mishap, if happen at oil and gas industry, could catch attention worldwide because the consequences, damage and loss of life are shocking.

Prior to entry of job, both permanent staff and those on temporary basis such as contractor, shall attend and pass examination of safety induction course conducted by NIOSH.

Prior to entry of the job site, it is again necessary that all staffs especially those on temporary basis, to participate the safety induction course again conducted by the plant safety officer. The latter one to include emergency response plan and route to safe area to gather if there is accident.

Job scope analysis, job safety analysis:

Prior to start work, employee to analyse and list out what to do, procedure, tools and possible danger and precaution.

Permit to work:

A permit to work must be obtained prior to start of work. It is necessary that the time of the work is suitable and obtain facilitation with other work ongoing.

Personal Protective Equipment:

Safety helmet, Safety Boots, safety harness, Coverall which is fire resistance, gas detector, safety googles

Safe practice/ act/ behavior:

All staffs shall be calm and patient at site. They shall obey all sign and rules. 

IEM PI Section A – Professional Responsibility related 1

(For PI section A, candidate will have to write an essay, which the question was earlier prepared by interviewers based on candidate’s Report on Training and Practical Experience. The following were predicted questions, by Mr. BAY based on his submitted report to principal interview and his trial exercise prior to sitting of PI.)


Professional Responsibility Related Question

What are professional standing that an engineer should stick to when he perceive there is serious inappropriate works were done and the safety and structural strength are at risk?

Introduction

Civil engineering project, both governmental related or private sector ones, often involve huge amount of money. All projects initiated and constructed therefore shall meet the intended use, benefit the public or meet the requirement of the owner. Otherwise, it is waste of time, efforts and money.

Engineers, both from consultancy team and contractor side, are the ones playing the roles in ensuring quality of work to meet specification, follow construction drawing and projects are completed within schedule and budget.

Therefore, engineers shall play their role to safeguard interest of their employer that works constructed products are safe and fit the intended use with no or minimum unnecessarily maintenance works due to inappropriate work method that could cause long term serviceability issues to the building owners.

In other words, we shall have firm standing that the interest of public and employers must be taken care. If there is inappropriate and poor quality work done and not meeting the requirement, rectification and reconstruction shall be instructed to contractor. Though this often cause unpleasant situation because the risk of project delay and possible project cost will be exceeded. However, our responsible and serious attitude will promote healthy working environment and make the construction industry sustainable.

For instance, I have encountered poor quality work of one of project that I have handled. The project is a factory and warehouse. There is 2-storey steel structure which is to support some numbers of heavy equipment on both the 1^st and 2^nd floor. When all the steel main framings were erected, we checked and inspected the bolt holes of almost all beam are enlarged excessively both on the web of steel beam and the fin (gusset). The edge and clearance between bolts are clearly not adequate. The structural strength and bolt (plate) bearing capacity (on the connected steel plate) are seriously jeopardized. Without further ado, we discuss to find rectification work. Though the contractor at first is a bit reluctant because of additional cost and delay in completion time, we as the engineers have expressed our firm standing on quality and safe structure is priority.

Conclusion

In working environment, there may be some situation make us hesitated to stand firm of right and proper decision especially that may involve huge amount of money. However, we shall be mature in thoughts. We shall play our roles as engineers. For the above paragraph, our role is to ensure works that done are safe and serve the intended use. 

IEM PI Section A – Management experience related 2

(For PI section A, candidate will have to write an essay, which the question was earlier prepared by interviewers based on candidate’s Report on Training and Practical Experience. The following were predicted questions, by Mr. BAY based on his submitted report to principal interview and his trial exercise prior to sitting of PI.)


Management Experience Related Question

What are the authoritative approval and procedure for a road enhancing work?

Introduction

Enhancement of road will be requested by authority such as JKR state and district when a project is at main road side of either federal or state road. It is a pre-requisite prior to planning approval especially the project occupies big area. The big development, once completed, will result high volume of traffic into and from the developed area into main road. Hence, it is reasonable that road enhancement being requested by authority to streamline the traffic at main road.

The following are items and stages of approval of proposed road enhancement work, which are needed to be presented and submitted to “Unit Pengurusan Projek Cawangan Jalan”, “Unit Keselamatan Jalan (Cawangan Jalan)”. Both the units are from JKR.

1)      Traffic Impact Assessment – traffic volume in coming future.

It is evaluation of current road and traffic situation plus projection (prediction) of future traffic condition of probably 10 years later.

The report shall be prepared by third party engineer, will cover current utilization of the road type (like federal road R5) and estimation (prediction) of the possible utilization in future due to grow of traffic and upon completion of new project.

The findings, as earlier paragraph, will be presented and recommendation will be included such as road enhancement and installation of traffic light system.

2)      Road safety audit-1 : Conceptual design dwgs.

This stage could have been started before TIA and shall be reviewed by road design engineer upon completion of TIA by another party. The conceptual design dwgs will have to be submitted to another appointed Road Safety Auditor.

The RSA auditor will be prepared a report with recommendation.

3)      Road safety audit-2 : Preliminary design drws.

This is next stage of RSA-1, preliminary design drws will have to be submitted to RSA auditor for his review and recommendation.

4)      Road safety audit-3 : Detailed design drws.

With permission from JKR, road design engineer could proceed directly to detailed design drws, without both RSA-1 and RSA-2. The detailed design shall cover proposed final road alignment, road furniture, traffic light system, relocation of utility, etc.

The detailed design shall take into consideration of all recommendation of TIA. Then, the design is submitted for RSA auditor for review and recommendation. 

5)      Road safety audit-4 (Stage 1, 2 & 3) : Construction and Traffic Management Drws (Stage 1), Corrective Action (Stage 2 & 3) prior to work approval.

There are 3 sub-stage for RSA-4.

The first sub-stage is construction and traffic management plan. This is planning of traffic management during construction work. A traffic management officer (TMO) will have to be appointed. The TMO will have to monitor and supervise the approved traffic management plan implemented effectively. Work approval will only granted by JKR if the traffic management plan and RSA-4 satisfy them.

The second and third of RSA-4 are corrective actions to traffic management plan and road construction works during ongoing construction. Supervision team members such the project Superintending Officer (S.O.) and engineer will have to ensure contractor to implement corrective actions prior to proceeding of works. 

6)      Road safety audit-5: Audit after issuance of CPC (approx. 3~6 months).

This is the last stage of the RSA process, which is to be carried out probably after 3 to 6 month after project completion and open to traffic. The RSA auditor, at this time, to check and review the efficiency of the design. Or else, recommendation and remedy work will be recommended.

Conclusion

For project, which is located next to main road (federal road) or when a new junction to main road is proposed, an independent Traffic Impact Officer will have to be appointed to conduct the study on the existing road and traffic and also the impact upon completion of project and new junction.

In addition, a road safety auditor who is independent too, will have needed to audit the road designer’s design, ongoing construction condition and as-built condition.

Both the TIA report and RSA of varies stages, though some stages may be omitted by JKR based on their jurisdiction, are required to satisfy JKR requirement prior to start work and takeover of the road. 

IEM PI Section A – Management experience related 1

(For PI section A, candidate will have to write an essay, which the question was earlier prepared by interviewers based on candidate’s Report on Training and Practical Experience. The following were predicted questions, by Mr. BAY based on his submitted report to principal interview and his trial exercise prior to sitting of PI.)


Management Experience Related Question

What are the roles and responsibility of a project engineer?

Introduction

A project engineer is to deal with authorities, client, consultant and contractor for the project. Depend on his employment, either employed by consultant or contractor, he is to deal and handle requirement from both the client and his employer such as quality of work, design issues, completion of work, cost control and facilitate the requirement from local authorities.

Design requirement:

If he is from consultancy firm, he shall liaise and make sure client’s requirement and concern are taken into consideration during the design stages. For instance, client may highlight floor crack problems of some of his existing warehouses and hope the new one won’t have similar problem.

Hence, he shall request to visit the existing warehouse to understand better the problem. Then, he shall spend his effort such as reviewing his joint layout for the slab.

If he is from contractor side, he liaise with design engineer or representative from consultant for the completeness of construction drawings and design requirement such as concrete grade, rebar grade, curtailment and anchorage details. He may also need to check the drawing, discuss with his construction manager, site staff and then again with design engineer for construction work.

Quality of work:

The project engineer, who is from consultancy firm, though may not be full time at site, still need to inspect the site work preferably together contractor staffs such as project manager and construction manager. He is the one to take care client’s interest on quality of site work.

In the other hand, the project engineer, who is from contractor side, is also need to ensure site work quality but more on importance of his contractor employer. He shall ensure quality of work and fulfil design requirement so that no Non-compliance record (NCR) issued to them which will incur extra time for rectification works and cost.

Completion of work:

Similarly to earlier paragraphs, which project engineers have to take care the quality of work and design requirement are followed. Project engineers, both from consultancy and contractor firm, have to monitor the construction works are on track to follow the construction schedule and no delay with their best efforts.

For the project engineer, who is from consultancy, his effort to monitor the site progress and completion date is to take care the business interests of his client. His client may have to start his business as planned.

For the project engineer, who is employed by contractor, his effort to monitor the completion date is to avoid Liquidated and Ascertained Damages (LAD).

Cost control:

Though it is primarily controlled by Project Manager, Quantity Surveyor and purchasing department, project engineers indeed are needed to facilitate and assist for successful cost control.

For instance, project engineer who is from consultancy firm and taking care interests of the project owner, will have better knowledge about possible variation order claims due to changes requested by client. If the changes are initiated during the construction after award of contract, he shall remind his client and advice a quotation from contractor prior to his decision.

On the other hand, if he is contractor’s project engineer, he shall keep record of site issues, progress, record and changes instructed by client and consulting engineer. It is important to facilitate his company claim if deemed reasonable.

Requirement from local authorities:

Apart from dealing with client, site staffs and employer, he shall liaise with authority too to ensure smooth execution of construction works.

The design consultant’s project engineer is to discuss and approach the local council for approval of his infra plan such earthwork, erosion and sediment control plan, project entrance and drainage discharge point.

The contractor’s project engineer is to check details as per approved plan are followed and constructed. If there is adjustment on the temporary works due to construction sequence and planning, he shall liaise with both consultant and inspecting officer from local council so that no pollutant was discharged to public drain and road.

Conclusion

Though the project engineers could be from either consultant or contractor, their roles and responsibility are looked similar. They shall take care design requirement, quality of work, completion date, cost control and follow up with authority’s requirement. They work together with their superior such as principal submitting engineer (consultant), their employer (consultant or contractor) and their colleagues (project manager, construction manager, supervisor, site engineer) for successful completion of project. 

IEM PI Section A – Site/ Field Experience related 1

(For PI section A, candidate will have to write an essay, which the question was earlier prepared by interviewers based on candidate’s Report on Training and Practical Experience. The following were predicted questions, by Mr. BAY based on his submitted report to principal interview and his trial exercise prior to sitting of PI.)


Site/ Field Experience Related Question

What are acceptance criteria of structural steel work?

Introduction

There are few items involved in the design, fabrication and erection of structural steel structure. Design engineer, steel fabricator and contractor are work together to ensure the quality and successful construction.

 The structural steel part is often the most expensive for typical industrial building. Hence, the acceptance criterion upon delivery to site are wised to decided and agreed by client, engineer and fabricator (erector) at early stage of construction.

There are the few items discussed here.

1)      Submission of Shop drawing

In order to avoid disagreement and argument upon of fabricated steel members (Assemblies) delivered to site not in accordance to design drws, engineer shall instruct the fabricator to submit shop drawing for review and comment.

2)      Welding procedure specification/ Method of statement on welding

a)      Flux-cored arc welding (FCAW) = semi-automatic or automatic arc welding process. No stick electrode.

b)      Stick Welding = Shielded metal arc welding (SMAW) = Manual arc welding (MMA/ MMAW)

Almost all steel assemble works inevitably involve welding works. The quality of welding affect the reliability and strength of structural steel. Hence, this part shall be submitted prior to commencement of mass fabrication work.  

Engineer’s inspection at fabrication yard to witness and inspect the trial welding work by qualified welder is also deemed necessary. Both the engineer and fabricator to discuss for the appropriate approaches.

3)      Inspection record form/ b4 delivered out from fabrication yard

All steel assemblies, prior to delivery out from fabrication yard, should have passed internal quality control system and in accordance to shop drawing and approved method statement. There shall be inspection record or similar form to check and tick all necessary work completed to required quality at yard.

4)      Type and number of test (Visual Inspection, UT test, MPI test)

a)      Visual inspection – to check uniformity of welds, surface condition like painting.

b)      UT test – to check internal flaw of the steel and weld.

c)       MPI test – to check surface and shallow depth of steel for flaw.

5)      Inspection and acceptance upon delivery to site

a)      personnel to inspect and sign the acceptance form.

b)      Visual inspection

6) Rectification work procedure at site, such field welding. 

IEM PI Section A – Design experience related 3

(For PI section A, candidate will have to write an essay, which the question was earlier prepared by interviewers based on candidate’s Report on Training and Practical Experience. The following were predicted questions, by Mr. BAY based on his submitted report to principal interview and his trial exercise prior to sitting of PI.)

Design Experience Related Question

What are the investigations needed for additional construction onto as-built structure? What are design concerns and practices should be taken?

Introduction

Additional construction to as-built and existing structure is challenging work and need due care and examination to the existing structure. It is especially true when the new or additional structure is proposed on top of existing one compared to extension at adjacent area of the existing one.

The following are some aspects that require engineer to study during the design process.

1)      As-built drawings

Examination to as-built drawing is essential. The purpose is to know the as-built structural framing such the beam arrangement and column layout. Their size and rebar details are also needed.

The examination of as-built drawings enable design engineer to produce early new structural framing on top of existing ones. With reference to as-built drawings, engineer could only decide when the new columns and supports shall be placed.

2)      Design load of as-built structure

The design report and design load of as-built structure is essential to facilitate design work of the additional structure. It is because total weight of the new items shall not exceed the supporting capacity of the as-built structure.

If this information is not available especially with existing structure which is built some time ago, the design engineer will have to be more conservative in assessing the structural capacity of the as-built and probably to do another thorough modeling and analysis together with the additional items.

3)      Structural system

Upon finish of table study on as-built drawing and design report, design engineer will have to consider the appropriate structural system such reinforced concrete system, structural steel or others.

For the project Aeon Shopping Mall Kulaijaya, which I have done and designed the new cinema platform onto as-built second floor rc system, I have decided to adopt structural steel with composite deck system. It is because there are plenty stepping platforms (different level) for cinema seats. If structural concrete system is adopted, there will be plenty of formwork needed, difficult to demobilize the formwork, the concrete member are also much heavier compared to structural steel.

4)      Field study and verification 

Field study of the as-built structure could help design engineer in their design too. It is because design engineer could feel better the clearance and possible discussion with contractor and fabricator regard to construction access, available equipment and machine for lifting of structural member within enclosed space.

By field study and discussion with contractor to know their construction management, design engineer could design better structural system such as beam or truss and possible the joint location to facilitate transportation and movement within enclosed space.

Conclusion

Unlike designing a total new structure, which design engineers to prepare the design based on requirement, design engineer will have to consider the as-built structural framing supporting new structure. New and additional structure shall not impair and damage the as-built one. Alteration and modification to as-built structure, if deemed unavoidable, careful study and proper detailing are needed. 

IEM PI Section A – Design experience related 2

(For PI section A, candidate will have to write an essay, which the question was earlier prepared by interviewers based on candidate’s Report on Training and Practical Experience. The following were predicted questions, by Mr. BAY based on his submitted report to principal interview and his trial exercise prior to sitting of PI.)

Design Experience Related Question

What are the design concerns for non-suspended ground slab and rectification method? Is the suspended ground to follow same design criteria? What the work procedure to strive for minimum cracking problem?

Introduction

Non-suspended ground slab is supported directly by earth throughout its area. The following aspects are design concerns for non-suspended ground slab.

1)      Drying Shrinkage 

Drying shrinkage is characteristic behavior of concrete. If the ground slab is restrained from movement, there will be locked-in stresses inside ground slab.

The strain in plain concrete, in accordance to BS8110: Part 2 is recommended 500x10-6 for calculation. This strain represents 1.5mm movement per 3m length. The resulted stress is 10N/sq.mm for concrete of Ec 20kN/sq.mm. This stress is often the cause of ground slab cracking.

2)      Thermal expansion

Similarly to drying shrinkage, the difference in temperature of the ground slab during day and night will also result the ground slab to expand and contract. The repetitive built-up and release of stresses is one cause of floor cracking.

3)      Creep effect of concrete

Creep is also characteristic behavior of concrete. Though it will reduce the adverse impact of concrete shrinkage, we do not rely on this in practice.

4)      Movement joint

Like loading, we provide reinforcement to resist stresses arisen from drying shrinkage, thermal expansion, etc. However, it is always not the practical and successful approach to control slab cracks.

The more appropriate method is to allow the ground slab to move. Hence, movement joints shall be stipulated at estimated location. In addition, saw cut line or crack inducers could control the crack pattern into more pleasant ways.

5)      Subgrade condition and modulus of subgrade reaction (K)

The earlier paragraphs are concerns related to characteristic behavior of concrete. The solution is provision of rebar and creation movement joint and saw cuts.

The slab thickness should also be checked with forces induced by the loading. Provision of thicker sub-base and well-compacted crusher run definitely could make stronger ground slab structure. It is because greater thickness of granular sub-base results greater value of modulus of subgrade reaction, K. Greater K value will result smaller moment forces of the ground slab.

The above are concern during design stages.

Works during construction are also very important to ensure good quality of non-suspended ground slab. During construction, the soften earth shall be replaced with suitable fill material and compacted. The whole area shall also be rolled and compacted by rollers and compacter. Top rebars shall be checked place closed to top surface as practical as possible. Joint and crack inducer line such saw cut shall be started the 2^nd days of concrete casting. 

IEM PI Section A – Design experience related 1

(For PI section A, candidate will have to write an essay, which the question was earlier prepared by interviewers based on candidate’s Report on Training and Practical Experience. The following were predicted questions, by Mr. BAY based on his submitted report to principal interview and his trial exercise prior to sitting of PI.)

Design Experience Related Question

What are the design principles/ criteria of pipe rack? What are the design horizontal forces, pipe shoe, fix shoe and free shoe? How to cater the vibration?

Introduction

Pipe rack, which is normally steel structure, to support pipes which the pipes are subjected to internal hydrostatic pressure or gas at high temperature. Structural engineers are to design the pipe rack to withstand both vertical and reactive actions from pipe to pipe rack both horizontally and longitudinally. 

 Design principle/ criteria

1)      Pipe stresss analysis and reactive force to pipe rack

It is piping engineer to conduct a pipe stress analysis. From the analysis, piping engineer to decide the pipe size, pipe loops and type of pipe shoe at strategic location. The type of pipe shoes are guide shoe, slide shoe and fix shoe (stopper). It is deemed highly necessary that piping engineer to provide the reactive force at these shoes especially at stopper to structural counterpart.  

Structural engineer will have to pay attention to type of shoes and the magnitude of the force. The force, especially at stopper, is a main concern for structural design of the pipe rack. Engineer to determine the bracing and size required.

2)      Type of pipe shoe

As per earlier paragraph, engineers need to pay attention to the type of pipe shoe. Guide shoe allow pipe to move longitudinally and slide shoe allow pipe to move both horizontally and longitudinally. As these shoes allow movement of the pipes, the reactive force exerted by pipes at these shoes are pretty much less severe compared to reactive forces exerted at stopper.  

For practical practice, slip forces at both guide and slide shoe can consider 10~20% of the operating weight of the pipe. The force at stopper is better referred to piping engineer for design value.

3)      Braced frame structure

Like all structural design, the horizontal force affects the lateral stability of structure. For pipe rack, the longitudinal and horizontal forces from pipes especially at stopper are to be taken care by design the appropriate structural system. It is always to adopt the braced framed system for an economical design. If the condition is not permitted, moment frame structure could still be designed with more attention to the steel connection design both the steel structural and footing. 

 How to cater the vibration?

Vibration of the pipe rack is caused by reactive force at stopper shoe. As the design and location of type of pipe shoe are prepared piping engineer, structural engineer is to design the pipe rack accordingly.