Project Engineering: Terminal 4 Changi Airport - Mech Power Generator

This report details a project engineer's involvement in the Terminal 4 Changi Airport project while working at Mech Power Generator PTE LTD. The project involved the installation of eight indoor synchronizing generators with power grid supply and five underground storage tanks. The engineer was responsible for scheduling, manpower control, equipment tracking, and ensuring compliance with Singapore standards, particularly SS535:2007 and SS 532:2007. Key activities included coordinating with consultants, managing the installation of generators and underground tanks, and conducting site acceptance tests. The report also highlights technical difficulties faced during site acceptance testing of underground storage tanks and generator synchronization, along with the solutions implemented, such as performing tank tightness tests and attending training on generator operation. The project provided valuable experience in synchronization with power grid supply and standby supervision of critical changeover testing, contributing to the engineer's familiarity with airport regulations and safety procedures.

Career Episode 2:
Introduction
2.1 I worked with Mech Power Generator PTE LTD from 28th
September 2010 till date. Mech Power has a leading
manufacturer in design, assembly, testing, installation,
commissioning, sale and service of diesel power powered
generator sets in Singapore. It also supplies the power
generation industry in the Asia Pacific region. It has achieved
several key certifications.
In Mech Power Generator, I worked as a project engineer. My
job scope requires me to lead projects and coordinate it
accordingly until it is completed, and ready for the final
handover.
Background
2.2 I have done many projects in my company. One of the
projects I would like to highlight about is the Terminal 4
Changi Airport project. It was different from my previous
projects PE 1.2. It contains of eight indoor synchronizing
generators with power grid supply, five underground storage
tanks with the different capacities and fuel pump systems.
2.3 The project was accomplished in 2 years. My job scope was
to schedule a plan, control manpower, track the equipment
delivery, production team, installation of the site work, and
ensured that the work done is aligned to the contract. I also
had to evaluate and ensure that our work complies with the
Singapore standard SS535:2007 code of practice that
involves installation, operation, maintenance, performance

and construction requirements of mains failure standby
generator systems.
Organization Chart

Personal Work Place Activity:
2.4 Project requires a person with a strong analytical mind,
resourceful, capability in handing project, inter personal skill,
and effective communication, with highly innovation.
Normally starting stage of the project, I studied carefully
about the terms of work scope with the tender drawing and
contract documents. PE 1.1 I understood the electrical and
mechanical design from the technical specification. PE 1.4I
developed the design team to clearly knows the customer
requirement, layout drawing to match with the approved
documents. PE 3.3 Make it work promptly I arranged a kick off
meeting while we get the order confirmation from the
customer.PE 3.2
2.5 For terminal 4 Changi Airport project required
synchronization to a power grid. During this process, I learnt
about the new electrical circuit drawing. I also attended a
training, to learn how to operate the generator of the
synchronization controller. PE 1.2, PE 2.4 This project consists of
two transformer supply to the building with emergency
source supply from UPS and Generator back up.
2.6 Project was very critical and very sensitive. Our system
supports the runway lightings power backup. If there is no
power supply in Transformer 1, we will change over to
Transformer 2. But if both transformers are not functioning,
our generator automatically starts. This supports the
emergency power sources. Once the power resumes, our
system will synchronize with the power grid supply, and
transfer the load to the power grid.
2.7 Our electrical panel are fabricated on our factory. I
coordinate with consultant and customer by propose the

date and sequence of testing. PE 3.4I arranged an internal
testing and quality check with our QA/QC team weekly basics
to increase the quality and productivity effectively. PE 3.6
2.8 Generators are located in the different locations inside the
building with 100liters storage tanks at each generator and
back up with the underground storage tank. Indoor
generator has a more installation works when compare to
the canopy generator. I planned and raised an order earlier
for the material lists like spring hangers, spring isolators, fuel
pipe materials, valves and exhaust pipe materials according
to the approved brand.
2.9 Manpower is planned in accordance to the project time
frame. Sufficient manpower decreased the time needed to
make delivery. The material and quality of our works are well
maintained too. PE 1.5
2.10 During the delivery we are accounted the few major things in
an account, the major was height limit of the entrance of the
building. There was a bridge along the delivery route,
according to the height limit I studied and arranged a low
bed trailer to pass by the routing. PE 2.1, PE 2.3
2.11 Safety are the main concern on each and every project but
for this project it was more to adopt. To achieve the greater
safety concern, we made a training program to our worker
and supervisor level with our safety department. We
organize the one new group for safety department with
safety manager, safety coordinator and safety supervisors to
make it efficient. PE 3.1 I planned to motivate them in safety

concern by awarding them with awards and gift vouchers, it
was more effective.
2.12 Delivered the generator earlier by maintain the proper
coordination by arranging the meeting clients, consultant
and made on internal meeting with our own team.
Installation completed effectively without defects. During
site acceptance test, we conducted the testing as same as
the factory acceptance test by arranging the external load
banks and power cables.
2.13 Underground tanks are complied with Singapore standard SS
532:2007 code of practice for the storage of flammable liquids
and BS 2594:1975 specification for carbon steel welded
horizontal cylindrical storage tanks. PE 1.6 After our Site
acceptance test onsite, they are conducted the integrated
system test to check the operation. This test includes our
underground storage tank and fuel pump system. There was
check list on our factory acceptance test by visual and
measure the size of the tanks on site. Our underground tank
made of Mild steel coated with the bituminous paint, after our
fabrication we test the welding joints by the approved
radiographic test procedure to make sure there was no
leakage. PE 2.2I involved in the radiographic testing to make sure
tested according to the Specifications. PE 1.3 We conducted
another pneumatic pressure test to find any leaks it was
passed and delivered successfully.
2.14 Underground tanks are undergoing site acceptance test
followed with the technical specification, continue
installation of the underground fuel piping works followed by
the pneumatic pressure test. After completion of the

installation works test the whole fuel system tested as per
the approved test format.
Engineering Skills and Knowledge Applied in the Work
2.15 Since this project was completed in 2 years, I had to apply
some of my core engineering skills and knowledge here. I
have applied few concepts like stress strain relations and
Hooke’s law for making the project much easy to complete.
As I had the core capability of understanding diagrams, flow
charts, drafts and any other information as well as
documentation. Moreover, I have understanding of
Singapore Standards and hence it was easier for me to make
my project successful. I was able to comply the underground
tanks with Singapore Standard SS 532:2007 codes of
practice. Being a mechanical engineer, I have my base
strong in mathematics and this knowledge has helped me in
my work. I even had to plan the manpower for our project
and make project delivery on time PE 1.5. My other engineering
skills and knowledge included geometric, dimension as well
as tolerancing. I even used my skill in trouble shooting
equipment for solving the issues faced in this project.
Technical Difficulties Faced and Solutions
2.16 One of the major technical difficulties that I had faced here
was during site acceptance test onsite. I was given the
responsibility to complete the underground storage tank test
PE 1.6. However, after matching my practical results with the
expected outputs, I observed that they were incorrect and
leakage was found. Since, we were completing the project
for Changi airport, it was extremely important to undertake
correct dimensions of the tank. For resolving this issue, I at

first performed tank tightness test. Primarily the tanks were
designed for 15000 gallons capacity and thus it was
important to check the unground storage effectively. I
ensured that the tank is made up of mild steel and welding
joints are being tested by the approved radiographic testing
process for ensuring zero leakage. Finally I was able to
obtain accurate results from the test.
2.17 The next significant issue that I have confronted in this
project was during synchronization of generator PE 2.3. As this
was the first time I was using this particular phenomenon, I
was facing difficulty. In an alternating current electric power
system, I was unable to match the speed and frequency of
the generator with my running network. This was one of the
vital steps in our project and due to this issue, it became
quite time consuming. Being the project engineer, it was my
responsibility to provide suitable solution for resolving this
issue. Hence, I started researching and finally was able to
learn about our new electrical circuit drawing. I even
attended training and workshops for knowing about the
working principle and finally was able to learn it. I checked
that there were two transformer supplied to the building
from generator back up and UPS. With such knowledge, I
was finally able to complete the generator synchronization
without much complexity PE 2.4.
Summary
2.18 This project work experience made me learn a new operation
like synchronization with power grid supply and learn the
testing by standby supervision of the critical change over
testing onsite. There was a good experience and I was happy
to saw the successful operation of the entire system. For this
project we are working on the airside and I under goes the
airport training course to much learn about the airside rules
and regulations clearly. I met a few teams of experienced
people and learned a new information regarding airport

safety. Profitably completed the project with the given time
frame, I always think about the cost savings with good
quality of work.PE 3.5
2.19 After successful completion of this project, I was familiar with
the application of airport passes, airside rules and
regulations.