Hi, I'm Noyal Thomson

Project 1: Dissolved Air Flotation (DAF) System | 1,000 m³/h

Involved in the full-scope delivery of a Dissolved Air Flotation (DAF) wastewater treatment system with a processing capacity of 1,000 m³/h to remove suspended solids, oils, and greases using micro-bubbles.

Scope of Work:

• Prepared preliminary and detailed engineering designs for the DAF system layout, including process flow, equipment positioning, and piping arrangement
• Produced detailed construction drawings and plans for site execution, coordinating between design and field teams
• Specified and arranged GRP (Glass Reinforced Plastic) piping to PN 16 pressure rating — selected for its corrosion resistance in aggressive effluent service, lightweight handling advantage, and longevity in wastewater environments
• Managed material take-off from drawings, procuring GRP pipes, fittings, flanges, and associated hardware from relevant departments and suppliers
• Scheduled and coordinated the workforce across installation phases — civil interface, piping, mechanical equipment installation, and testing
• Supervised the full system installation from groundworks through to piping hook-up, equipment mounting, and pre-commissioning checks
• Completed all regulatory and safety documentation (method statements, risk assessments, permit-to-work forms) in compliance with site HSE requirements
• Inspected welds per applicable Welding Procedure Specifications (WPS) — verifying joint preparation, process parameters, and post-weld condition
• Supervised protective coating application — ensuring correct surface preparation standards, coating thickness, and holiday-free coverage on piping and structural elements

Key Technical Details:

• System Capacity: 1,000 m³/h
• Piping Material: GRP (Glass Reinforced Plastic)
• Pressure Rating: PN 16
• Application: Industrial effluent / wastewater treatment

Project 2: Samnan Effluent Pumping Station | 5,000 m³/h

Contributed to the installation of a large-scale effluent pumping station at the Samnan Industrial Area, Sharjah, serving a design throughput of 5,000 m³/h for industrial wastewater collection and transfer.

Scope of Work:

• Prepared detailed design drawings and installation plans for the piping and valve layout across the pumping station
• Arranged and managed the supply of PN 16 piping, valves, and associated fittings — coordinating procurement across departments to align with the construction schedule
• Supervised and executed the installation of high-pressure piping and valve assemblies to PN 16 rating, including isolation valves, non-return valves, and gate valves at pump discharge headers
• Managed on-site technical issues — resolving clashes, fit-up challenges, and sequencing conflicts as they arose during construction
• Coordinated workforce scheduling across multiple concurrent installation fronts within the pumping station
• Completed safety and regulatory documentation for all works, including confined space protocols and pressure system documentation
• Conducted weld inspections per WPS at critical joint locations on the pressure piping system
• Supervised coating inspection on buried and exposed piping to ensure corrosion protection compliance

Key Technical Details:

• Station Capacity: 5,000 m³/h
• Piping & Valves: PN 16 rated
• Application: Industrial effluent pumping and transfer

Project 3: Al-Sajaa Pumping Station | PN 25 Piping, Valves & Surge Tank

Worked on the Al-Sajaa Effluent Pumping Station, a high-pressure infrastructure project involving PN 25 rated piping, valves, and surge tank installation for water hammer protection.

Scope of Work:

• Prepared preliminary and detailed designs for the PN 25 piping system, valve arrangements, and surge tank integration
• Produced detailed installation drawings, incorporating pipe routing, support design, valve locations, and surge tank tie-in points
• Arranged materials and equipment from drawings — including PN 25 rated pipes, flanged gate valves, check valves, and surge tank with associated instrumentation connections
• Supervised the installation of PN 25 high-pressure piping and valves, ensuring correct flange alignment, bolt torqueing sequences, and gasket selection for the elevated pressure class
• Oversaw the mechanical installation and pressure-side connection of the surge tank, including inlet/outlet piping, isolation valves, pressure relief arrangements, and anchoring
• Managed workforce allocation and work scheduling across the pumping station construction site
• Handled on-site engineering problems — addressing design vs. field condition conflicts and implementing approved solutions
• Performed weld inspections in accordance with WPS — checking joint fit-up, welder qualification, process compliance, and visual/dimensional quality of completed welds
• Supervised coating and lining inspection on the surge tank and associated buried/exposed piping

Key Technical Details:

• Pressure Rating: PN 25 (higher pressure class than standard effluent systems)
• Components: High-pressure piping, valves, surge tank
• Application: Effluent pumping with pressure surge protection

Project 4: Elevated Storage Tank Maintenance (1,000 m³)

Led the preventive maintenance supervision of a 1,000 m³ elevated storage tank at the Samnan Effluent Pumping Station to ensure structural and mechanical integrity for plant buffer storage.

Scope of Work:

• Supervised all preventive maintenance activities on the elevated tank structure, including tank internals, external shell, roof, nozzles, manholes, and structural supports
• Prepared and managed maintenance schedules and work plans, coordinating shutdowns to minimise operational disruption
• Arranged maintenance workforce, equipment, and materials — including access platforms, inspection tools, and repair consumables
• Completed safety regulatory documents — including working-at-height permits, confined space entry procedures, and isolation certificates for tank isolation from the live system
• Inspected weld integrity on tank shell seams, nozzle welds, and structural connections per applicable WPS and inspection standards
• Supervised coating condition assessment and recoating works — evaluating coating breakdown, surface preparation (blasting standards), primer and topcoat application, and final DFT (Dry Film Thickness) verification
• Identified and escalated maintenance findings, contributing to the long-term asset maintenance record of the station

Key Technical Details:

• Tank Capacity: 1,000 m³
• Type: Elevated storage tank
• Application: Effluent pumping station buffer storage

Structural Frame Design

• Designed a 3D truss front structure using mild steel (MS) sections, with each member calculated to carry and distribute expected load paths under off-road conditions
• Frame was designed to integrate with the existing two-wheeler chassis, forming a rigid unified structure
• Wheelbase set at 100 cm width; link lengths and geometry derived from steering stem angle constraints to maintain original wheel-to-wheel axis alignment
• Upper arms positioned in the same vertical plane with triangular inclination matching the knuckle angle, ensuring geometrical accuracy during suspension travel

Steering System Design

• Designed a T-shaped steering rod mechanism; perpendicular members connected via nut and bolt arrangement with rubber ring seals to prevent play and reduce vibration transfer
• Steering input transmitted to front wheels through knuckles using a locked nut-and-bolt arrangement — enabling precise directional control on uneven terrain
• Original fork assembly removed and replaced with a custom steering rod supported by a V-member fastened to the handlebar

Suspension Design

• Front: Independent suspension system — each wheel moves independently, improving traction and stability on rough surfaces
• Rear: Mono-shock suspension — eliminates torsional load on the swing arm, providing consistent braking and handling behaviour
• Knuckles connected to upper and lower arms via ball joints; suspension units fixed at drilled cross-member holes using hooks and bolts
• Rear shock pre-load adjustable via threaded collar for varied load conditions

Braking System Design

• Rear-only hydraulic disc brake system selected based on braking torque analysis to ensure axle integrity under maximum deceleration
• System comprises: brake disc, caliper, master cylinder with dual-piston output, and hydraulic hoses
• Master cylinder dual-piston arrangement chosen to maximise line pressure; brake pedal and master cylinder mounted on the front structure frame

Powertrain Selection

• Two-stroke engine selected for its high power-to-weight ratio, mechanical simplicity (no valves), and suitability for off-road conditions
• Engine placement designed to avoid heat transfer to accessories, mountings, and driver; vibration frequency assessed to prevent resonance with the frame
• Separate oil tank lubrication system adopted to prevent spark plug fouling and carbon buildup in the cylinder

Material

• Primary structural material: Mild Steel (MS) — selected for its weldability, availability, machinability, and sufficient yield strength for the applied loads

Machining Operations

• Turning — used for shafting, axle preparation, and cylindrical component finishing
• Drilling — cross-member holes for suspension mounting, bolt hole preparation across frame joints
• Boring — precision hole sizing for bearing and bushing fits
• Milling — flat surface preparation on frame joints and bracket mounting faces to ensure tight, load-bearing contact surfaces

Welding — Arc/Stick Welding (SMAW)

• All structural frame joints, chassis integration welds, and bracket attachments executed using Shielded Metal Arc Welding (SMAW)
• Weld joints designed and executed at critical load-bearing nodes of the 3D truss structure, ensuring full penetration at primary connections
• Frame-to-chassis integration welds carried out to form a rigid, single unified structure capable of withstanding dynamic off-road loading
• Post-weld inspection performed to check for surface defects, undercutting, and joint continuity before assembly proceeded
• Strengthening rods welded at identified high-stress zones of the front structure to reinforce against bending and torsional loads

Assembly

• Engine decarbonised (carbon deposits removed from cylinder liner and piston), gear box cleaned and re-oiled, then reassembled
• Engine, carburettor, air filter, and fuel tank installed and integrated onto the fabricated chassis
• Wheels bolted to knuckles at four points per wheel; suspension units hooked and bolted into position
• All fasteners secured with appropriate torque; rubber seals applied at steering joints

Material — Alloy Compositions

Jominy End Quench Test

• Specimens austenitised at 850°C–900°C for uniform carbon distribution and homogeneous austenite phase formation
• End-quenched per ASTM A255 to create a controlled cooling rate gradient along the specimen length
• Hardness measured at standardised intervals from the quenched end (1.6 mm to 44.5 mm)

Vickers Hardness Testing

• Applied load: 30,000 gf (30 kgf)
• 21 measurement points per specimen along the longitudinal axis
• Hardness values (HV) plotted to generate comparative hardenability curves

Specimen Preparation for Microstructural Analysis

• Sectioned at key distances using precision cutting equipment
• Mounting — specimens cold-mounted using PolyFast/DuroFast mounting resins
• Grinding & Polishing — progressive abrasive grinding followed by fine polishing to mirror finish using automated polishing equipment
• Ultrasonic Cleaning — high-frequency cavitation cleaning to remove abrasive residue before etching
• Electrolytic Etching — selective corrosion of grain boundaries and phase interfaces to reveal microstructural contrast

Microscopic Analysis

• Equipment: Nikon Eclipse LV100NDA Optical Microscope
• Lenses used: 5X (overview), 20X (phase distribution), 50X (fine microstructural features — martensite laths, bainite plates)
• Illumination modes: Brightfield, darkfield, and polarised light for phase contrast enhancement

Vickers Hardness Profiles

ZS590 consistently maintained higher hardness values across all distances, confirming superior hardenability due to its higher manganese content.

Microstructural Findings

ZK645 transitioned to softer phases (ferrite, bainite) earlier along the specimen, indicating lower hardenability but improved toughness and ductility.

AutoCAD Drafting

• Drafted HVAC system layouts, building services drawings, and water treatment facility layouts using AutoCAD
• Translated senior engineer mark-ups into construction-ready drawings, maintaining revisions across project phases

Structural Analysis — ANSYS (FEM)

• Performed finite element analysis on water tank enclosures and steel frames to validate stress profiles under hydrostatic and operational loading
• Prepared analysis summaries for senior engineer review and design sign-off

Engineering Documentation

• Maintained Bills of Materials (BOM), material submittal records, and drawing registers
• Ensured documentation accuracy and version control throughout project delivery

QA/QC & Procurement Support

• Assisted in QA/QC reporting, pressure testing, and commissioning witness activities during mechanical installations
• Supported procurement through material requisitions, submittal reviews, and delivery tracking