Malcolm Hewling |
Position:
| Associate
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| Location:
| Wakefield
| Date of Birth:
| 9th November 1950
| Education:
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| Recent Training and CPD:
| - NEC 3 - Engineering and Construction Contract - 2 day course
- CSTS Confined Space Training
- CCNSG - Safety Passport Training
- Finite Element Analysis
- CDM Regulation & CE Marketing
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| Career History:
| - Undertook a 4 year Technician Apprenticeship, including 1st year EITB training parts A & B in Mechanical Engineering at Newton Chambers Engineering.
- Continued at Newton Chambers in various roles of increasing responsibility from estimator draughtsman through to design engineer responsible for the design of general heavy engineering products associated with steelworks production. Joined a technical sales team responsible for producing detailed designs, cost estimates and technical specifications from clients / consultants requirements for water control / barrage gates and their associated operating equipment.
- Under Boving & Company Limited gained promotion to Senior Design Engineer / Section Leader responsible for major projects related to both steelworks plant and the water control industry.
- Promoted to Chief Design Engineer under Kvaerner Boving taking responsibility for control and supervision of all gate designers including annual appraisals and workload planning as well as cost estimation and control for all gate projects. Focused on water control projects and the design of various types of gate/ barrage installations together with condition assessments and costed refurbishment reports for several hydro-electric installations throughout the world.
- Under General Electric I retained the position of Chief Design Engineer in the Waterways Centre of Excellence department and remained responsible for supervision of all gate designers together with responsibility for global tendering, designing and planning associated with gates.
- Joined Kenneth Grubb Associates Ltd in January 2006 as a consultant senior designer in the water control / barrage industry and promoted to Associate status January 2007.
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| Relevant Project Experience - Kenneth Grubb Associates Ltd
Portora Barrage - Enniskillen
Appointed project manager responsible for the site inspection, design and supervision of manufacturing drawings and specifications and production of installation method statements and risk assessments for replacement of 4 off 13m span x 4.26m deep lattice girder wheel gates for the Portora Barrage in Enniskillen Northern Ireland.
Glendoe Hydro-Electric Project - Scotland.
Appointed project manager on this prestigious project encompassing gates, screens and stoplogs for the complete Glendoe Hydro-Electric project. The scope of works include the production and supervision of designs and detailed manufacturing drawings, the production of risk documents and outline design specifications for Bottom Outlet, Headrace Intake, Tailrace Outfall and Aqueduct Outfall screens, stoplogs, wheel gates, cranes and associated lift beams and storage equipment.
Phuoc Hoa Irrigation Project - Black & Veatch - Vietnam.
Seconded to Black & Veatch in Ho Chi Minh City as gate specialist to review local consultants design for the Phuoc Hoa Irrigation scheme. Undertook two visits reviewing Radial gates, wheel gates, stoplog and screen designs and provided a detailed report on proposal drawings and associated calculations. Worked closely with Black & Veatch Engineers and local Vietnamese Engineers in developing the scheme. Visited local hydropower station to view locally manufactured equipment.
Washlands Flood Protection Scheme - Dagenham.
Appointed project manager responsible for design, supervision of manufacturing drawings for a 4.87m span x 2.75m deep vertical lift wheel gate and hoist for the Washlands flood protection scheme. The hoist comprised a unique design having facility to disconnect the drive mechanism and provide additional hand wind facility and chain hoist operation.
Relevant Project Experience - GE Energy UK Ltd
Maidenhead, Eaton & Windsor Flood Alleviation scheme, UK
Appointed as Project Designer on this scheme I was responsible for the supervision and control of design development and production of manufacturing drawings for the overall supply of the flood gates on this scheme.
The scope of supply comprised 3 No 7.0m span x 5.0m deep Servo operated Radial gates and 2 No 10.7m span x 2.9m deep servo operated fishbelly flap gates and their associated operating equipment.
Along with the overall responsibility for the gates on this project I personally designed the radial gates which were of particular interest being single arm box section structures operated / raised by the servo push force these being located below each box section arm.
Each radial gate also incorporated an integral sevo operated discharge flap for fine tuning of the water level and the discharge of trash.
Glasson Dock Flap Gate extension, UK
As part of the Environment agency scheme to raise the West coast retention levels local to the Lancaster / Carlisle areas it became necessary to raise the height of an existing 15.8m span x 9.2m deep, servo operated, bottom hinged flap, dock entrance gate.
As Project Designer I was responsible for the design of the 2.0m extension of the gate together with a design check on the whole of the existing structure which also involved calculation of the increased operating forces to size a replacement hydraulic cylinder suitable for the increased operating load.
As the increased height dock gate was above the local quay levels, 2 small flap gates were designed to seal the gap between the dock gate and the new civil impoundment walls.
The dock gate has a pedestrian walkway across it's top and an interesting part of which was the hinged and sprung hand railing which prevented damage when the gate was lowered into silt.
John Kerr Draft tube Bulkhead gates, USA.
As part of an overall hydro-electric power station refurbishment GE were asked to supervise the design and supply of 3 new draft tube slide gates each 5.13m span x 4.65m deep.
As Project Designer I was given the responsibility of not only being involved in the supplier selection process but with liaison with the chosen supplier to supervise and review their manufacturing drawings and specifications.
Ceannacroc & Invergarry power station refurbishment works, Scotland.
Having been involved in the original inspections and tender appraisals for the Ceannacroc and Invergarry power station refurbishment works I was pleased to be appointed Project Designer as this gave a chance to follow the project through from start to finish.
Both Ceannacroc and Invergarry refurbishments were large projects overall and not only involved refurbishment of varying sizes of existing gates and trash screens but also supply of new equipment either to be used during the refurbishment process or to replace irreparable equipment.
A major part of the new supply were the Invergarry intake screens and trash raking equipment comprising 5 sets of screen panels each set being 6.0m span x 10.5m deep and a new bosker raking system complete with runway beam and supporting structure.
My responsibility on both of these projects also included the compilation of gate training documents and undertaking operative classroom training at site.
Ffestiniog power station Intake gates condition assessments, Wales.
Following an initial inspection and technical report in 1999 on increased impoundment levels I was asked to inspect the same gates annually and report on the condition with respect to further deterioration of the gates and the refurbishment requirements.
Each gate is checked for general condition and general loss of material / paintwork by ultrasonic devices.( Elcometer & Flaw detector )
The control gates are counterweight assisted and are raised and lowered via lifting chains by an electrically operated winch unit.
Relevant Project Experience - Kvaerner Boving
Claw and Mayfair Barrage gates, Zimbabwe.
Claw and Mayfair dams, in Zimbabwe, are for water storage and each have radial gates, stoplogs, lift beams and gantry cranes for control of water and maintenance of equipment. As Project Designer I was responsible for the control of the whole project, which included 4 No radial gates 13.72m span x 6.3m deep, 3 No radial gates 17.0m span x 5.65m deep and associated stoplogs and chain hoist operating equipment, and the production of detail designs for the radial gates and their operating hoist and counterweight requirements. The radial gates are counterweight assisted and the operating equipment is of an unusual design with Galle chains connecting to the gate and a wire ropes connecting to the counterweight. A taper rope drum to the counterweight allows almost fully balanced conditions to be achieved giving an acceptable handwind torque.
Owen Falls Power Station refurbishment, Uganda.
The Owen Falls hydro-electric project was built in 1950 and generates power utilising water from Lake Victoria discharging down the Nile. The refurbishment project comprised a combination of refurbishment of existing equipment and the supply of new. I was involved in scoping and costing the gate portion of the supply prior to being nominated as Project Designer. Apart from ensuring all of the refurbishment requirements were met I also produced the detail designs for 6 No new hydraulically operated vertical lift sluice gates each 3.0m span x 5.1m deep, 1 No vertical lift tube roller gate 3.0m span x 5.1m deep and a floating boom barrier for the power station intake.
River Tees Barrage, UK
I was appointed Project Designer for this highly prestigious project comprising a river barrage of five fishbelly flap gates, a navigation lock complete with mitre gates and sluices and a canoe slalom intake gate with associated stoplogs and operating / lifting equipment. Apart from supervision of the overall project I also produced final designs for the barrage flap gates, barrage stoplogs and the navigation lock stoplogs together with the requirements for barrage gate model testing which was undertaken at the hydraulics research laboratory in Wallingford. The five barrage gates which are each 13.5m span x 8.0m deep and weigh 50 tonne are operated from one side only by a single hydraulic cylinder. The gates are fully sealed and hence buoyant and were floated into position during installation. The navigation lock is 6.0 m span and includes 3 sets of timber mitre gates and 2 sets of steel stoplogs and an automatic lifting beam. For this prestigious project I contributed to the Technical paper on the Tees Barrage project in the Institution of Civil Engineers - Municipal Engineer September 1995 and contributed during the seminar November of that year.
Muela Hydro Electric power station Draft tube flap gates, Lesotho.
To isolate the turbines for maintenance or repair 3 top hinged flap gates were provided complete with operating cylinders and vacuum box assisted closure. As Project Designer I was responsible for designing the gates, each 2.7m span x 1.42m deep, sizing of the hydraulic operating cylinders and calculation of the vacuum forces which assist in holding the gate in the open position. The gate has unusual features such as external drive cylinders requiring specialised shaft sealing and pressure bonnet designs. On this project I was also responsible for the compilation of gate training documents and for undertaking operative classroom training.
Song Hinh Spillway Radial Gates, Vietnam.
As project designer I was responsible for the design and supervision of production drawings for 6 No 12.0m span x 13.5m deep spillway radial gates for the Song Hinh hydro-electric project in Vietnam. Each gate weighed approximately 80 tonnes and comprised a 3 section leaf fabrication and box section radial arms.
Tailrace Stoplogs for Rannoch Hydro Electric power station in Scotland.
To replace an existing timber stoplog system used to isolate a power station tailrace channel I was required to produce a stoplog design that would fit inside an existing groove and also design a suitable monorail hoist system which would enable installation and removal. The final design of the stoplogs comprised a set of 3 No units each 5.2m span x 1.5m deep with special side grooves comprising of rolled steel sections with machined sealing faces.
Kainji Dam Hydro-electric Power Station, Nigeria.
My involvement on this project was to visit the site in Nigeria and undertake a full visual inspection of all the gate equipment, produce a refurbishment report and estimate the cost of such refurbishments for inclusion within our bid.
The power station is very large with 24 intake screens and hydraulically operated vertical lift intake wheel gates each 4.9m span x 10.5m deep serving 12 turbines of capacities varying between 80MW and 130MW.
There are draft tube slide gates, 6 No large spillway with radial gates, spillway stoplogs and navigation lock complex with control gates and stoplogs.
Kariba Dam Hydro- electric power station, Zimbabwe.
As with the Kainji Dam project my involvement in this was to visit the site in Zimbabwe and undertake a full visual inspection of all the gate equipment, produce a refurbishment report and estimate the cost of such refurbishments for inclusion within our bid. Kariba is also a very large station with many and varied large gates and screens etc.
Erochty & Pitlochry power stations in Scotland.
As part of an overall refurbishment program by Scottish & Southern Energy the hydro-electric power stations at Erochty and Pitlochry were selected for inspection. My involvement in this was to visit the both sites and undertake full visual inspections of all the gate equipment, produce a refurbishment report and estimate the cost of such refurbishments for inclusion within our bid to client.
Ffestiniog power station in North Wales.
As part of a proposal to increase the impoundment levels of the Stwlan dam in North Wales it was my responsibility, as project designer, to check that both the 2 No intake bulkhead gates and the 2 No intake control gates, which control flow from the dam to the Ffestiniog Hydro-electric power station, would be suitable for the proposed increases in water load. Both sets of gates are 4.4m span x 4.4m deep and were supplied in about 1956. They are of riveted construction and, in the case of the control gate comprise materials no longer available or in general use today. This project involved a detailed inspection of the existing bulkhead slide gates and stoney roller control gates and their associated built in parts to enable recalculation of the existing structures both as originally designed and in accordance with modern practice. The original 1999 inspections and report prompted customer to request that an annual inspection of this equipment be undertaken.
Pergau Hydroelectric Project, Malaysia
On this project I was responsible for the compilation of gate training documents and for undertaking operative classroom training.
Relevant Project Experience - Boving Newton Chambers
Redcar Steelworks Energy Recovery Turbine, UK
Awarded the Project Designer role for this prestigious turnkey project my responsibilities included all of the mechanical aspects of the energy recovery turbine at Redcar steelworks together with being resident engineer on site throughout the installation and commissioning period. My responsibilities also included the compilation of training documents and undertaking operative classroom training on site.
Erinle River Dam Spillway Radial Gates, Nigeria.
Project designer responsible for the design of 3 No spillway radial gates each 8.0m span x 6.0m deep complete with electrically driven rope winch and cross shaft.
Chelsea Harbour Bascule bridge, UK
Responsible for the design of a 6.0m span x 3.0m wide bascule bridge for Chelsea Harbour. This bridge was used for emergency fire tender access across the lock.
Internal Quality System
Part of a team responsible for staff training on company procedures to achieve BS5750 status.
Relevant Project Experience - Newton Chambers Engineering Ltd
Water Control Sales.
As part of a technical sales team responsible for tender designs and cost estimations I worked on several projects both for UK and overseas. Two typical UK projects were the Scots Float sluice radial gates for Southern Water Authority and the Swansea marina sector gates for Swansea City Council.
Dry Coke Cooling System, UK
Part of a special projects team, reporting to the projects manager and responsible for the supervision of 3 subordinates, converting mechanical designs from Russian to British Standards of a "Giprokoks" dry coke cooling system.
National Nuclear Corporation, UK
Part of a team contracted to research and develop parts of a liquid Sodium reactor for the National Nuclear Corporation.
Energy Audit, UK
Compilation of Newton Chambers Engineering Limited stage 1 energy audit comprising detailed energy loss calculations and boiler sizing requirements.
Fume Cleaning Plants UK
Licensed to provide the Bischoff wet scrubber fume cleaning system for blast furnaces I worked on several projects for the British Steel Corporation such as Llanwern fume cleaning in South Wales, Ravenscraig fume cleaning plant in Scotland and the Kish extraction plant at Normanby Park in Scunthorpe. Each of these projects included a wide variety of design aspects such as structural steelwork, pipework and flows in pipes and tank / pressure vessel design.
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