Mohammad Zainal M. Yusof

Preliminary Measurement of Welding Fumes in Automotive Plants

The preliminary measurement of welding fumes was conducted by means to get firsthand experience and understanding the welding fumes issues in automotive assembly plant in Malaysia. Personal sampling pumps were provided to a human welder of highest risk in the assembly section. Series of direct reading measurement for area sampling of particulate matters 2.5µm or less in diameter size (P.M 2.5 ), toxic gases and temperature were also conducted at the same time. The welding fumes sample were then analyze by scanning electron microscope with energy dispersive spectroscopy (SEM-EDS). Questionnaires were distributed to the welders for questionnaires pilot test purpose in order to determine welders knowledge on welding hazards and persistent symptom experience by each welder. Results of the study show that welding fumes contains the highest element of cobalt and nickel. Carbon monoxide (CO), carbon dioxide (CO 2 ) and ammonia level were well below the standard level. Results from the mean score questionnaire analysis shows the welders posses limited knowledge of welding fumes hazard and not sure of the health effects of welding fumes There are eight persistent symptoms that had been experience by at least 50% of the welder. This preliminary study had successfully identified suggestion and alteration towards the actual measurement that will be conduct on the next stage.

Experimental Study on Welding Fumes Exposure from Aluminum Metal Inert Gas (MIG) Process

Welding fumes are known as hazard that can cause acute health effects. Welders exposures to welding fumes are oftentimes difficult to evaluate due to the different parameters settings exist in their workplace. Therefore, this experimental study focused on welding fumes exposure towards aluminum metal inert gas (MIG) welders. The experimental set-up was done by using a dummy welder and a welding machine attached to Computer Numerical Control (CNC) workbench for programmable welding route. This preliminary experiment aims at comparing results between scanning electron microscope with energy dispersive spectroscopy (SEM-EDS), inductively coupled mass spectroscopy (ICP-MS) and atomic absorption spectrometry (AAS) analysis method. New insight on the consistency of the SEM-EDS experimental results, comparison of element detected by using SEM-EDS and ICP-MS result analysis and the different elements detected between standing and sitting welding position were recognized through this preliminary experimental study. It is concluded that SEM-EDS analysis are not suitable to be used as a preliminary analysis to shortlist the metal elements exists in the welding fumes sample due to the misleading results if compared to the elemental characterization measure proportional to the atomic number such as ICP-MS.

Sub-index derivation of welding health-hazard index (WHI) for small and medium enterprises (SMEs) in Malaysia

Malaysia is a developing nation and the manufacturing sector is the major contributor to the Malaysian economy. In the year 2009, Small and Medium Enterprises (SMEs) contribute to 28,840 establishments which represented 94.2 percent of the total establishments in the manufacturing sector in Malaysia. Welding is a common industrial process in manufacturing sector that has both acute and long term chronic hazards mainly from the inhalable welding fumes. Welding fumes assessment in SMEs welding workplace is essential in order to ensure the minimum level of exposure is maintained as required by the prevailing standards. However, providing concentration or emission information alone is insufficient and meaningless to the workers and company management. There is an urgent need to develop an index which served as a ranking tool in comparing environmental condition at different location and to simplify complex health hazard issues of welding fumes that can be comprehended easily by the workers and company management. Preliminary ideas on the derivation of the sub-index from rating of health effect, mixture hazard, doses and weightage of metal fumes element were outlined in this paper. At the end of this paper, future works regarding aggregation factor and verification of the index were also discussed.

Energy consumption in residential building: The effect of appliances and human behaviour

Electricity is the predominant energy source used in these buildings. Therefore, energy management in residential buildings requires serious attention to ensure the energy consumption in residential building have been managed properly. Currently, the unstable of fuel price give the big impact to electricity price. Due to the issue, consumers require to use electricity more wisely. Using energy efficiently is one of the solution to reduce energy consumption. This paper aims to propose an initiative strategy for energy management system based on an analysis of energy consumption in residential building. The level of energy consumption among the occupants was found by obtaining electricity bills and distributing a questionnaire. A case study was carried out in selected areas in the Southern Zone of Peninsular Malaysia. The results of the study show that energy consumption was significant increased by month and the EEES as one of energy management system was suggested.

Determination of Important Parameters and Technical Characteristic for Welding Fumes Index Development by Using QFD Approach

This paper discussed on the determination of important parameters and technical characteristic for the development of a welding fumes index by using Quality Function Deployment (QFD) approach. Welding fumes index is developed with the objective to enhance the welding workplace safety and health. Index simplifies complex health-hazard issues of welding fumes to be comprehended easily by the employees. Questionnaires on welder desire to know the various welding fumes health effects that exist in their workplace were distributed among welders of a selected automotive assembly lines in the state Pahang, Malaysia, during a pilot case study. Results of the questionnaires show that all the customer requirements (irritants effect, sensitizer effects, respiratory system effect, systemic toxin effect, reproductive toxins effect, carcinogen effect, mixture effect) were equally important to the welders. The relationship between the customer (welder) requirement and technical characteristic were established whereby important technical characteristics were shortlisted. Development of welding fumes index according to employees demand will increase the knowledge and awareness on occupational safety and health among employees. The paper provides the main idea on development of welding fumes index taking into consideration the needs of the customer i.e. welder.

Experimental and CFD modelling for thermal comfort and CO2 concentration in office building

Computational fluid dynamic CFD was used for simulating air flow, indoor air distribution and contamination concentration. Gases pollution and thermal discomfort affected occupational health and productivity of work place. The main objectives of this study are to investigate the impact of air change rate in CO2 concentration and to estimate the profile of CO2 concentration in the offices building. The thermal comfort and gases contamination are investigated by numerical analysis CFD which was validated by experiment. Thus the air temperature, air velocity and CO2 concentration were measured at several points in the chamber with four occupants. Comparing between experimental and numerical results showed good agreement. In addition, the CO2 concentration around human recorded high, compared to the other area. Moreover, the thermal comfort in this study is within the ASHRAE standard 55-2004.

Pulmonary Function Status among Welders in Malaysian’s Automotive Industries

Welding process has potential physical and chemical health hazards. Welding fumes, toxic gases and metal particles are the chemical hazard that leads to long-term and chronic lung function effects. This study investigates the effects of duration of exposure and smoking status on pulmonary function status among welders of two automotive assembly plants in Malaysia (Plant 1 and Plant 2). This study assesses 61 male welders by pulmonary function test (PFT) using spirometer. These welders worked with spot, metal inert gas (MIG) and robotic welding without the benefit of fume control ventilation or respiratory protective devices. Welding workers in both plants showed significant reduction in lung function parameters relative to controls. The results of the study also showed that in Plant 1, smoking status influence significantly on pulmonary function status. However, in Plant 2, duration of work and smoking status both influence significantly on welders pulmonary function status. This study provides information to welders on chemical hazard effects among Malaysia’s automotive industries.

Monitoring of Selected Indoor Air Quality Parameters and Cooling Energy Usage in Hotel Restaurant Malaysia

Sensible (temperature) and latent (moisture) loads are the common load an air-conditioning (AC) system need to handle. Both loads are generated from conditioned space, internal source and outdoor air ventilation. This study is to monitor the indoor air quality IAQ in hotel restaurant and the results are compared with Malaysian standard MS1525 and Industry Code of Practice (COP) on IAQ 2010, Department of Safety and Health (DOSH) Malaysia. The AC system performance was also monitored to identify the actual cooling energy usage base on standard operations. Psychrometric chart was used to analyse the actual cooling energy required and identified the latent and sensible loads significantly. The result of the study shows the mean air temperature, relative humidity (RH), carbon dioxide (CO) and carbon monoxide (CO2) levels were within range as stipulated by standard and code of practice. Heat loads analysis on a psychrometric chart showed the total cooling energy as 296.2 kW; of which 196.3 kW was contributed to primary air unit (PAU) and 99.9 kW to air handling unit (AHU) respectively. The primary contribution for sensible and latent loads and recommendation of potential energy saving also been discussed to meet energy efficient in AC system while maintaining good indoor air quality in the restaurant.

Energy Saving Measures for University Public Library: A Case Study of UTHM Library

Energy is an important source of power for human daily activity. Energy efficiency is measured by the productivity of the system which goes through under certain condition as to achieve results at optimum level. The basic purpose of this study is to reduce and save energy consumption in order to determine the energy efficiency of public university library. Thereby saving measures can be identified from the building services installed in the library. From the findings, there are two major system correlates which is mechanical and electrical system. Based on these systems, it could resolve intricacy issues regards to building efficiency by conducting an Energy Saving Measures (ESM) in context of Malaysia’s tropical setting. Lack of supervision and excessive wastage of energy will render inefficient in both systems which would decrease the optimum level of performance and reliability issues. The study emphasizes that energy conservation should be prioritized in order to avoid unregulated energy consumption. Hence, it could focus on the main streamline where energy efficiency is a possible and potential sustainable building in the present and future for better surroundings and standard quality of life.

Comparing Cooling Energy between Existing Air-Conditioning System and Proposed Design System

Air-conditioning (AC) system is typically used to remove the sensible and latent heat loads in buildings. It provides cool and dehumidified air to meet the occupants comfort and good indoor air quality (IAQ). Improper design and analysis of AC process resulted in high cooling energy and unsatisfied indoor humidity level in tropical climate. The objective of this study is to identify the cooling energy in hotel restaurant by comparing the design with proper fresh air ventilation design. The hotel restaurant was designed with primary air unit (PAU) and air handling unit (AHU) as to remove sensible and latent loads. The performance of the AC system has been monitored and analysed using psychrometric chart. For the AC air side system, 296.2 kW of cooling energy was used in standard operation. An alternative design was proposed for the said hotel restaurant employing only one AHU, with a cooling capacity of 165.9 kW which was 43 % lower than the existing system. The difference in temperature, humidity ratio and air flow rate influenced the cooling energy for AC system.