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EDITION:
TECHNOLOGY
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EXPERIMENT: PRE- EFFECTIVE DATE:
COMMISSIONING, COMMISSIONING AMENDMENT
AND START-UP
DATE:
FACULTY OF ENGINEERING TECHNOLOGY
DEPARTMENT OF CHEMICAL ENGINEERING TECHNOLOGY

BIOPRODUCT FACILITY DESIGN LAB

LABORATORY INSTRUCTION SHEETS

COURSE CODE BNN 40104

EXPERIMENT NO. 5
PRE-COMMISSIONING, COMMISSIONING AND START
EXPERIMENT TITLE
UP OF FLOW OVER WIERS APPARATUS
DATE 30 SEPTEMBER 2019
GROUP NO. 2
DR NUR HANIS HAYATI BT HAIROM
LECTURER/INSTRUCTOR/TUTOR PUAN MASAYU BINTI MASLAN
ENCIK MOHAMAD SIDIQ BIN MOHD BASIR
DATE OF REPORT SUBMISSION 7 OCTOBER 2019
ATTENDANCE/PARTICIPATION/DISIPLINE: /5%
INTRODUCTION: /5%
PROCEDURE: /15%
DISCUSSIONS: /50%
CONCLUSION /10%
DISTRIBUTION OF MARKS FOR SUGGESTIONS & RECOMENDATIONS /5%
LABORATORY REPORT: REFERENCES: /5%
FORMAT/OTEHRS /5%

TOTAL:
/100%

EXAMINER COMMENTS: RECEIVED DATE AND STAMP:

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STUDENT CODE OF ETHICS

DEPARTMENT OF CHEMICAL ENGINEERING TECHNOLOGY

FACULTY OF ENGINEERING TECHNOLOGY

I hereby declare that I have prepared this report with my own efforts. I also admit to

not accept or provide any assistance in preparing this report and anything

that is in it is true.

1) Group Leader (Signature)

Name : MUHAMMAD LUQMAN BIN YUSOF
Matrix No. : DN 160341

2) Group Member 1 (Signature)

Name : ROHARDIYANA BINTI ROSLAN
Matrix No. : DN 160345

3) Group Member 2 (Signature)

Name : ASWINI A/P PURUSHOTHANAN
Matrix No. : AN 160118
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1.0 OBJECTIVES

To gain the knowledge and techniques that can be applied in pre-commissioning,

commissioning and start-up of equipment.

2.0 LEARNING OUTCOMES

At the end of the study, student will be able to:

1. Develop high understanding on the commissioning and start-up of bioproduct plant
(C5, PLO4).
2. Display the ability to analyze problems, develop methods for their solutions and
begin to demonstrate a capacity for independent critical thought (P5, PLO2)
3. Demonstrate teamwork skills and lead the team members effectively in conducting
laboratory work and solving problem for the assigned project. (A3, PLO9)

3.0 INTRODUCTION

3.1 Flow over Weirs

Weirs are a structure, used to dam up a stream or river, over which the water flows, is
called a weir. The conditions of flow, in the case of a weir, are practically the same as
those of a rectangular notch. That is why, a notch is, sometimes, called as a weir and vice
versa. The only difference between a notch and a weir is that the notch of a small size and
the weir is of a bigger one. Moreover, a notch is usually made in a plate, whereas a notch
is made of masonry or concrete.
There are many types of weirs depending upon their shape, nature of discharge,
width of crest and nature of crest. The most widely used weirs are rectangular shape
opening and (V) notch. Therefore, in this experiment will study about both of most
common used weirs. The theory of this experiment is the weir structure will increase the
water level, which will be measured. In addition, the existing of stilling baffle helps to
collect the water and disperse the water flow slowly to ensure minimum turbulence
effect.
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3.2 Types of Weirs

1) Rectangular shape opening

The rectangular weir can measure higher flows than the v-notch weir and over a wider
operating range.

3
2
Q = Cd B 2g H 2
3

Where , Cd =Coefficient of discharge

B = Width of notch
H = Head above bottom of notch
Q = Flow rate

2) V- notch
The V-notch weir is a notch with a V shape opening. V-notch weir is typically used to
measure low flows within a narrow operating range.


5
8
Q= Cd 2 g tan H 2
15 2
Where, Cd = Coefficient of discharge

= Half the enclosed angle of the vee.
2
H = Head above bottom of notch
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4.0 INSTRUCTION

4.1 Pre-commissioning
1. The equipment for flow over weirs were checked to ensure the equipment and all existing
parts were similar as the drawing provided.
2. There was no cleaning step in pre-commissioning because the process are using only
water as the actual process fluid and required none cleaning.

4.2 Commissioning
1. The equipment was set as shown in the equipment drawing.
2. The hydraulic bench pump was checked to ensure it was securely connected.
3. The collection tank drain valve was checked it was opened to allow flow discharge back
into the sump tank.
4. The weirs were set on the hydraulic bench and all thumb nuts were checked to ensure all
were secured.
5. The Vernier gauge was set to zero to check whether there was zero error or not.
6. The pump was started, and the flow controller was adjusted to minimum flow of water
into the stilling baffle.
7. Any leaking or unusual flow were observed during the constant minimum flow and listed
in the punch list.
8. The commissioning step were repeated for the maximum flow rate of water.

4.3 Start-up
1. The flow control valve was adjusted to from minimum flowrate until maximum flowrate.
2. During each flow, the flow was observed, and the time taken for it fills up the tank were
taken to each flowrate.
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4.4 Experiment
1. The weir apparatus was leveled on the hydraulic bench and the rectangular notch weir
was installed.
2. The hydraulic bench flow control valve was opened slowly to let water flow into the
channel until water discharge to the weir plate. The water level was ensured to be
constant over time.
3. The flow control valve was closed, and water level were allowed to be stabilized.
4. The Vernier gauge was set to a datum reading and placed at the halfway between
notch plate and stilling baffle.
5. The water was allowed to flow in and stabilized and reading was taken in every
increasing of about 1 cm.
6. The reading of volume and time taken to fill up the tank was taken to determine the
flow rate.
7. Step 1 to 6 were repeated for v-notch.
8. The results were recorded.
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5.0 DISCUSSIONS

1. RESULTS AND CALCULATIONS

Rectangular Notch

Rectangular Volume Height Height Time (s) Flow Rate, Log H

Notch (L) (m) Level Q (m3/s)
3 0.0461 Min 19.82 1.5136x10-4 -1.3363
3 0.0460 Min 19.94 1.5045x10-4 -1.3372
3 0.0866 Max 3.85 7.7922x10-4 -1.0625

Rectangular Log Q Q2/3 (m2/s2/3) Cd H/B

Notch -3.8200 2.8401x10-3 0.1569 1.3970
-3.8226 2.8288x10-3 0.1565 1.3939
-3.1083 8.4679x10-3 0.3138 2.6242

Calculation of Flow Rates, Q (m3/s):

Flow Rate, Q (m3/s) = Volume of Water (m3)/Time (s)
Q1 Q (m3/s) = 0.003 Q2 Q (m3/s) = 0.003 Q3 Q (m3/s) = 0.003 m3/3.85s
3 - 3
m /19.82s = 1.5136x10 m /19.94s = = 7.7922x10-4
4
1.5045x10-4

Calculation of Log Q:
Log Q
Log Log Q1 = Log Log Log Q2 = Log Log Log Q3 = Log
Q1 (1.5136x10-4) =- Q2 (1.5136x10-4) = - Q3 (1.5136x10-4) = -
3.8200 3.8226 3.1083

Calculation of Log H:
Log H
Log Log H1 = Log Log Log H2 = Log Log Log H3 = Log
H1 (0.0461) =-1.3363 H2 (0.0460) = -1.3372 H3 (0.0866) = -1.0625

Calculation H/B:
H/B
H1/B 0.0461/0.033 = H2/B 0.0460/0.033 H3/B 0.0866/0.033 = 2.6242
1.3970 =1.3939

Calculation of Q2/3:
Q2/3
Q2/3 Q2/3 = (1.5136x10- Q2/3 Q2/3 = (1.5136x10- Q2/3 Q2/3 = (1.5136x10-4)2/3
4 2/3
) = 2.8401x10-3 4 2/3
) = 2.8288x10-3 = 8.4679x10-3
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Calculation of Coefficient of Discharge, Cd

3 1
• Rearrange Formula of Rectangular Notch, 𝐶𝑑 = 2 𝑄 ( 3 )
𝐵√2𝑔𝐻 2

Cd
Cd1 3 1
Cd1 = 2 (1.5136x10−4 ) ( 3 ) = 0.1569
0.033√2(9.81)(0.0461)2
Cd2 3 1
Cd2 = 2 (1.5045x10−4 ) ( 3 ) = 0.1565
0.033√2(9.81)(0.0460)2
Cd3 3 1
Cd3 = 2 (7.7922x10−4 ) ( 3 ) = 0.3138
0.033√2(9.81)(0.0866)2

V- notch

V - Notch Volume (L) Height (m) Height Level Time (s) Flow Rate, Q (m3/s)
3 0.0795 Min 22.80 1.3158x10-4
3 0.1071 Max 4.31 6.96056x10-4
3 0.1071 Max 4.14 7.24638x10-4

V - Notch Q2/5(m6/5/s2/5) Cd
2.8033x10-2 0.03126
5.4583x10-2 0.07849
5.5469x10-2 0.08172

Calculation of Flow Rates, Q (m3/s):

Flow Rate, Q (m3/s) = Volume of Water (m3)/Time (s)
3
Q1 Q (m /s) = 0.003 Q2 Q (m3/s) = 0.003 Q3 Q (m3/s) = 0.003
m3/22.80s m3/4.31s = m3/4.14s = 7.24638x10-
-4 -4 4
=1.3158x10 6.96056x10

Calculation of Q2/5:
Q2/5
2/5 2/5 - 2/5
Q Q = (1.3158x10 Q Q = (6.96056x10-
2/5
Q2/5 Q2/5 = (7.24638x10-
4 2/5
) = 2.8033x10-2 4 2/5
) = 5.4583x10-2 4 2/5
) = 5.5469x10-2
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Calculation of Coefficient of Discharge, Cd

15 1
• Rearrange Formula of Rectangular Notch, 𝐶𝑑 = 8
𝑄( 𝜃
5 )
√2𝑔tan⁡( 2 )𝐻 2

Cd
Cd1
15 1
𝐶𝑑 = 1.3158−4 ( 5 ) = 0.03126
8 90
√2(9.81)tan⁡( 2 )0.07952
Cd2
15 1
𝐶𝑑 = 6.96056−4 ( 5 ) = 0.07849
8 90
√2(9.81)tan⁡( 2 )0.10712
Cd3
15 1
𝐶𝑑 = 7.24638−4 ( 5 ) = 0.08172
8 90
√2(9.81)tan⁡( 2 )0.10712
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Pre-commissioning and Commissioning

Figure 1.0 : Shows the drawing of fluid weir apparatus that need to be evaluate during Pre-
commissioning
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a) b) c)
Figure 2.0 (a): show the evaluation on all fittings are tightly connected to the pump and working
properly, (b) show the evaluation on inlet valve use to control the water flow rate, (c) show the
wheel is lock up before conducting the experiment.

d) e) f)
Figure 3.0 (d), (e) : shows the fluid weir apparatus is properly installed and evaluate before start-
up, (f) The pump is switch on and try run for the first time to ensure the apparatus is working
properly.
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Punch List

g) h) i)

Figure 4.0 (g), (h): shows the screws attach to the weir plate are loosen cause water penetrate
along the screws, (i) shows the pump unstable producing high flowrate, cause level to fluctuate
over time.

2. ANALYSIS

Rectangular Notch
Table of Q2/3 and H

Q2/3 (m2/s2/3) H (m)

2.8288x10-3 0.0460
2.8401x10-3 0.0461
8.4679x10-3 0.0866

Graph of Q2/3 Against Head Above Bottom of Notch, H

0.009
0.008
0.007
Q2/3 (m2/s2/3 )

0.006
0.005
0.004
0.003
0.002
0.001
0
0.046 0.0461 0.0866
Head Above Bottom of Notch (m)
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Table of Log Q and Log H

Log Q Log H
-3.1083 -1.0625
-3.8200 -1.3363
-3.8226 -1.3372

Graph of Log Q Against Log H

0
-1.0625 -1.3363 -1.3372
-0.5
-1
-1.5
-2
Log Q

-2.5
-3
-3.5
-4
-4.5
Log H

Table of Cd and H
Cd H
0.1565 0.0460
0.1569 0.0461
0.3138 0.0866

Graph of Coefficient of Discharge, Cd Against Head Above

Bottom of Notch, H
0.35

0.3

0.25

0.2
Cd

0.15

0.1

0.05

0
0.046 0.0461 0.0866
Head Above Bottom of Notch, H
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V-Notch

Q2/5 H
0.1565 0.0795
0.1569 0.1071
0.3138 0.1071

Graph of Q2/5 Against Head Above Bottom of Notch, H

0.35

0.3

0.25

0.2
Q2/5

0.15

0.1

0.05

0
0.0795 0.1071 0.1071
Head Above Bottom of Notch (m)

3. DISCUSSION
Fluid Weir

From this experiment, the flow rate and the coefficient of discharge for flow over a
triangular and rectangular notch are determine by using the Basic Weir apparatus. The
discharge coefficient is the ratio of the actual discharge to the theoretical discharge.
Firstly, based the result obtained, it is observed that the trend of the coefficient
discharge for rectangular are increasing as the flowrate increase. As the height increase, the
Cd also increase. This was because the difference of values of height was in wide range.
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Secondly, For V-notch, Cd values is higher as the height of increment increase. If the
width of the weir is less than the channel width so that the flow is forced to contract
Compare to the rectangular notch, the Cd are much higher than rectangular notch since the
smaller increment change of height resulted much higher in Cd. Thus, increase of height,
flowrate, constant volume is affecting the coefficient of discharge. Means, the water is
discharge higher as the coefficient of discharge is increase.

A triangular notch gives more accurate results for low discharges than rectangular
notch and the same triangular notch can measure a wide range of flows accurately.
Therefore, there is differ value Cd for both rectangular notch and V-notch. The triangular
weir has the advantage that it maintains a high weir head H even for small flow rates
because of the decreasing flow area with decreasing H, and thus it can be used to measure
a wide range of flow rates accurately. The theoretical Cd of V-Notch in range between 0.58
and 0.62. the value Cd that obtained from the experiment are quite large. This can be
assumed due of the apparatus that have some leakage and the pump is not properly
working.

Pre-Commissioning Process

Pre-commissioning is a sequence evaluation need to execute to ensure the condition of

the apparatus is in a respectable condition regarding to the manual drawing. The aspect of
checklist must be examined before the commissioning and start up procedure. Based on
checklist, the drawing apparatus must be checked first to ensure the apparatus is same with
the diagram. Next, the water splitter of the apparatus is inspected to ensure it is flow
downward. The flow from the stilling buffer is need in laminar flow condition. Before
conducting the experiment, the Vernier height gauge is set to zero reading. Check the weir
plate is in good condition due to prevent from leaking before starting the experiment. The
pump is inspected to make sure it is working properly.
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Commissioning Process

Commissioning process is confirmation process used to approve that facility has been
design, procured, fabricated, installed or prepared according with is drawing and
specification (Garcia, 2019). Before running the experiment, we also done commissioning
process to instrument. Before run experiment, the connection of outflow, inflow and
overflow must be checked and free from leakage. The hydraulic bench pump was checked
to ensure it was securely connected. This to prevent from leakage during run the
experiment. The collection tank drain valve was checked it was opened to allow flow
discharge back into the sump tank. This is to ensure the water is circulate properly, without
causing the experiment to halt during running. The weirs were set on the hydraulic bench
and all thumb nuts were checked to ensure all were secured. This to prevent from water
flow through the nuts/screws.

The Vernier gauge was set to zero to check whether there was zero error or not. This is
to ensure; the height measurement is taken correctly. The pump was started, and the flow
controller was adjusted to minimum flow of water into the stilling baffle. The experiment
conducting with the minimum and maximum flow due to determine Cd accurately. Any
leaking or unusual flow were observed during the constant minimum flow and listed in the
punch list. The punch list is important to ensure the apparatus is working properly in
future.
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6.0 CONCLUSION

The smooth flow over the weir is important in order to identify the accurate flowrate. As
such, pre-commissioning and commissioning are vital to be carried out before start-up
of the equipment. In the experiment, pre-commissioning, commissioning and start up
are activity that bridge these phases which involve system turnover, system checkout,
system commissioning and performance testing. Via these phases, one can lead to a
more successful startup of an experiment. The important of punch list is also understood
during commissioning which is to ensure the apparatus is working properly in future.
Based on the readings obtained, it is also found that a triangular notch gives more
accurate results for low discharges than rectangular notch and the same triangular notch
can measure a wide range of flows accurately. In short, the objective of this experiment
to obtain knowledge and techniques that can be applied in pre-commissioning and start-
up of equipment was achieved.

7.0 SUGGESTION AND RECOMMENDATIONS

In order to ensure an accurate reading can be obtained, pre-commissioning and

commissioning are carried out. This is to certify that the equipment functions well. It is
also to make sure that all flow enters by travelling over the weir and not around the weir
or under the weir. Before doing the experiment, it is also better to learn and understand
first on how to conduct the experiment to prevent errors such as parallax or technical
errors. It is also vital to check the equipment present based on its manual and the
equipment picture given during pre-commissioning to recognize any missing or fouled
parts. For instance, failed Vernier caliper on the flow over weir equipment can cause
inconsistent reading and lead to wrong flowrate determination. Besides, the results
obtained from rectangular notch and v-notch must be written in 4 decimal points to get
accurate values. Repeating the experiment three times and taking the average reading
reduces chance of reading error.
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8.0 REFERENCES

Covey, Geoff. (2013). Pre-commissioning. Appita Journal. 66. 122-126.

Kandaswamy, P. K., & Rouse, H. (1957). Characteristics of flow over terminal weirs
and
sills. Journal of the Hydraulics Division, 83(4), 1-13.
Irzooki, Raad & Akib, Shatirah & Fayyadh, Moatasem. (2014). Experimental Study of
Characteristics of Flow over Weirs with Semicircular Openings. Arabian Journal
For Science And Engineering. 10.1007/s13369-014-1360-8.
Rao, S. S., & Shukla, M. K. (1971). Characteristics of flow over weirs of finite crest
width. Journal of the Hydraulics Division, 97(11), 1807-1816.
Subramanya, K., & Awasthy, S. C. (1972). Spatially varied flow over side-
weirs. Journal of
the Hydraulics Division, 98(1), 1-10.
https://www.academia.edu/18747051/CHE241_-
Lab_Report_Solteq_Flow_Over_Weirs_FM26_2015_
https://www.scribd.com/doc/34695544/Flow-of-Water-Over-Weirs
https://en.wikipedia.org/wiki/Fluid_mechanics
Sam Mannan, Frank P. Lee, Lee's Loss Prevention in the Process Industries: Hazard
Identification, Assessment and Control, Volume 1, Elsevier Butterworth
Heinemann, 2005. ISBN 978-0750678575. (Google books)
R. L. Daugherty and J. B. Franzini, Fluid Mechanics, 6th ed. (New York: McGraw-Hill,
1965). pp. 338-349.

Prepared by/Disediakan oleh : Approved by/Disahkan oleh :

Signature/Tandatangan : Signature/Tandatangan :
Name/Nama : NUR HANIS HAYATI HAIROM Name/Nama : PROF. MADYA DR. ISHAK BABA

Date/Tarikh : Tarikh :
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APPENDIX
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