This journey by two amateur university students would not have been possible if were not for some of the most generous and benevolent men. One of them was a wise and experienced man in the electric motor business, Uncle Ali. We bought motor for the machine from him in March. While searching for the materials, we visited his shop multiple times to learn from him about operational knowledge of electric motors and model definitions in the market.

Meantime, we bought a tempered shaft and spindles, in order to prepare them and cut necessary key-slots as per our design, to transmit power from the motor to the toroid. We bargained for a cheap deal with a workshop near Uncle Ali’s shop. Later, we bought joining parts such as: silicon glue, nuts and long metal threads to cut into bolts. Much of our saving was depleted by then. So, when it was time pay for our motor & gear-box setup, Uncle Ali noticed us nervously laughing while counting our money outside his shop. He probably overheard us joking that, what a major legwork it would be for us to walk 5 kilometers carrying an approximately 40kg motor-setup on feet; since, we would not have anything left in our pockets after paying for this.  

Because, when we were handing-over the purchase money, Uncle Ali said that, he did not need the money right then and gave back about 40% of the cash. We promised to pay him back within next two months. We shaked on it like men, and left with the motor-setup hiding our teary joy. Gladly, we were able to return the money within 35 days.

Carrying different parts & tools weighing about 50kg in total, from our apartments to the university by walking and on public transports proved to be very difficult. Indubitably, annoyed quite a few people during the morning-rush. That is why, we summed up some money to transport the motor setup in an Uber ride. Though, the first two drivers outright refused to carry such heavy load. Nonetheless, we were glad and relieved to bring the all required parts to our university laboratory.

The mild-steel rusts rapidly in the humid weather of Dhaka. Thus, we started searching for “spare” paint mixtures soon after. Since, the expensive marine-grade epoxy paint (highly erosion resistive water repellant coating) consisted of 3-part chemicals & pigment, and were sold in gallons. We contacted multiple painters and shops all over Dhaka, to buy only a small amount (just enough for the parts). We remember visiting countless places and waiting for hours after our daily university classes, just to get turned down in the end. Finally, our persistence caught the eye of a shop-keeper of a major paint shop. He was able to gather some spare amount of each chemicals from different painter-contractors to sell us in small bottles. We were super excited to acquire actual ship-body paints for our machine at a reasonable price.    

Meanwhile, our supervisor Dr. Ahmed used all his authority to convince the administration to designate a spot for us in the underground Fluid Laboratory. With the favor from the university construction contractor we dug up the concrete floor and installed a strong base for the bearings to uphold the moving toroid. We bought dinner for the two laborers who helped us that evening.

The whole construction process was arduous. After all, we were doing multiple jobs and making this machine, seven days a week with limited sleep. Meantime, we could not afford to invest in buying safety equipment, nor were able to replace faulty/risky power-tools. So, we had to be extra careful with our dealings and had our own means of safety measures. Such as: wearing rubber slippers when connecting power tools and holding black-tinted glass over the welding arc etc. My favorite one was operating the tiny drilling machine: one pushing down the lever while the other cooled off the job pouring cooling water from a mug; while, both simultaneously holding down the job on the flat surface of a large hydraulic slip ring supported by stacks of bricks. None of us faced any major injury, but our health was deteriorating rapidly. Every night we returned home numb & drained. Thus, we had to take a week’s rest, due to continuous fatigue. Fortunately, all the big parts were complete by then.

Despite all the odds, we were determined to complete the construction of the parts before the next semester began. Since, we would be entering the senior year at the college, the most difficult & the most important academic year.

After the one-week break from the workshop, we returned with full vigor to work on the final details of the parts. The home-workshop was basically us working in the small open space in front of the toilet shared by multiple families and a tiny unofficial storage. Thus, the rainy season was a major hindrance. We cramped under storage roof to continue our work when it rained (at least a relief from the scorching sun). However, the electricity was often cut-off during storms or heavy rains. Then, we would study the research papers and make the experimental plans. No matter what, we were always at Uncle Manik’s workshop. We created a tight bonding with that place.

25^th May. The last night was the hardest. We worked till very late. All soaked in rain & dirt. But we were pushing to finish the work no matter what and take the machine parts home (since our apartments were closer in distance than the university). Meantime, it was hard to comprehend that, we would not be returning there anytime soon. Everyone became emotional. Uncle Manik gave away one of his grinding tools. We could not thank him enough for everything he did.

Almost every day after our classes or jobs, we would go to see Uncle Manik at his job-workshop and discuss about our machine. It allowed us to closely observe a mechanic’s handiwork. Sometimes even we pitched-in to finish his daily job-orders early. So that, he would have more time to devise with us after work. Meantime, it also allowed us to get some on-hand experience. Uncle Manik made few of our machine parts at his job-workshop while showing us the ropes. But, the intensive works started when our semester break began.

Uncle Manik generously welcomed us to work at his home-workshop during the semester break. We were grateful to him for such opportunity. He lived far across the river. We had to take boat-ride every morning. There we worked 12 hours a day. However, we still had to maintain our jobs to fund this research project and for our expenses. So, our visits to his place was intermittent. It was also best when the mechanic present at his house, so we could work with his guidance. Thus, we were always there on the weekends or holidays, to take his time. In return, we could only offer a little amount of money as workshop fee; which, Uncle Manik strongly resisted. Hence, we tried to repay his kindness as much as we could, by often buying foods & snacks for his family, and with our utmost gratitude.

Primarily the parts and bits of the toroid tester machine are handmade. A literal result of hard work, labor, blood and sweat. We were eager to learn and aspire ourselves to work by our hands. Also, it was greatly economical. In example, a wide metal sheet was bent only once. Later, side was cut-off and hammered to make the inner wall with smaller diameter (went almost deaf after hammering for 4 hours straight!). Utilizing the methods those somewhat seemed primitive by look but tactically effective in practice. Difficulties were faced and we had to be pragmatic. The design changed throughout the building procedure. But, nothing too drastic or diverged from the original plan. Such as: due to early cutting mistakes, there was shortage of metal. So, instead of making full-circle flange ring, we only welded on arcs to join the parts. Then again, when glass shop mistakenly shortened the width of our glass-window pieces. We welded bits of metal pieces to make increase the height of the side support.

The most crucial factor that we have learned about the field-work is that, always minding and incorporating design allowances for each of the parts. The factor of safety is met in that procedure as well. Afterall, everything will evolve from the original diagrams due to material availability, method viability and financial restrains.

The bewildering fact that even common engineering materials had their perverted alternate local names, baffled our bookish brains. You have to know what to ask for, and where to ask for. We were thrown into a world where it felt like our educated guesses and learned knowledge were ineffective. Thus, locating the places to acquire the desired engineering materials proved to be very difficult. We scoured through almost every notable place of the Dhaka city and traveled to almost all the outskirts, in the search for information.

The greater Nawabpur and its surrounding area holds its name to have collective numbers of shops & warehouses (near 3000) to supply all sorts of materials for engineering needs. But, its convoluted alleyway and overcrowded (with people and products new or pawned) narrow streets, can be daunting for any citizen or buyer. Fortunately, we grew up in such chaos of ghetto areas of Old Dhaka. Yet, finding the right thing seemed like its own campaign. Scraped metals, pipes, tiny parts, motors and every other things had their own designated blocks in Nawabpur (but indistinguishable to unfamiliar eyes). After walking through all the nooks & corners for weeks we finally mapped out the names of alleyways and their specialty. We bought about everything from this hood. Unfortunately, most glass-cutter did not dare to cut a donut shaped glass with large inner diameter. Doubting their glass integrity and fearing of wasting the product. We even went as far as Megha Port (outside the city) to find the suitable kind of glass dealer. Finally, we happened to meet someone from Mohakhali area, who took upon the task to cut such odd shaped glass for us.

We were fully aware of the prerequisite spontaneity, that is to be adaptive with the machine design as we looked for the available materials in the common market.

We were already contributing in our families and saving up money on the side to participate in engineering project competitions. Since, we determined our academic future, we decided to invest in the independent research. From the beginning we knew it is going to be bit costly for us and tough. However, we believed our industrious mindset will persevere through any impediment. (Means we had the rare skills to persistently bargain and work hard like no other.) Later, seeing our enthusiasm, even our kind supervisor helped us with some emergency purchases.

Thus, with solicitous support from our supervisor Dr. Ahmed, we rushed to buy full amount of iron required for the machine. Buying scrap mild-steel sheets by weight was lot cheaper than regular deals. These sheets just needed good amount of scrubbing, which posed no inconvenience to us. Meanwhile, we became very close to an experienced mechanic of Dholaikhal area, Mr. Manik Mazumder. He adored us like nephews because, we were sincere students pursuing higher-studies. Uncle Manik agreed to become our mentor to guide us through the building of the machine. We showed him our drawings, and he introduced us to the tools & techniques to make it reality.

11^th November 2017, it was the first day of last semester of our 3^rd year in college. Typically, about everyone came to the University early and the class was hanging out merrily at our spot. But, two of us, were feeling bit lost. Depressed regarding the fact that, other than attending routine classes just for good grades, we were not actually preparing for the future. From the beginning of Junior year, most of us started seriously pondering about the plans after Bachelors. Coincidently, both of us had grown quiet the liking toward the deepwater petroleum technologies. Specially, the petroleum exploration and extraction processes, that correlated with mining as well. Gradually, we also became aware about the bleak reality that, there is insufficient research facilities and about no job opportunity, for off-shore engineering in our country. We decided (more like pledged!) that, we are going to earnestly indulge ourselves into continuous self-learning and specialize on petroleum engineering in the Masters abroad. Therefore, we needed a project to apply our newly gleaned knowledges for better understanding. On that faithful day, we mustered up the courage to request our common most favorite teacher, to conduct an independent research under his supervision.

Right that day, we visited our professor Dr. Dewan Hasan Ahmed, and expressed our worries & passion regarding our future. Surprisingly, this humble gentleman, one of the most senior faculty took his valuable moments, actually to listen to our whining & blabbering! After that, he listed us full guidelines on conducting an engineering research step by step. He himself noted down the things for us on his pad, sent links to our email right-way and introduced us with Nitish Ranjan Sarker (a former faculty of our university), who recently finished his Masters in Petroleum Engineering abroad. Felt like we were being metaphorically spoon-fed for the first time in our adult life. We left his office super excited!        

We began looking into possibilities of various research topics related to Petroleum Engineering. After studying about hundred papers and consulting with Nitish Sarker, we proposed our supervisor with the plan of researching on pipeline material wear due to slurry transportation. However, to execute that, we must construct a tester for conducting such research. Since, no institution facilitates such tester. Our supervisor advised that, a Toroidal Material Wear Tester with transparent side window would be most versatile for wide range experiments and closely resemble the mechanics of material wear during pipe-flow. Additionally, it would help us to study the fluid dynamics of multiphase flow as well. Dr. Ahmed assured his constant support and said that, it is going to be challenging but most fruitful if we can actually make it. We vowed to give our utmost effort.    

We started with the papers by Nitish Sarker. It introduced us to the research world of toroid testers. Cooke et al (1996, 1999, 2000) traced back to the earliest works for coal degradation by Worster & Denny (1955). Traynis (1977) added to the earliest design. Their revolutionary ideas created the base for modern PCCE’s Toroid Tester. Henday’s (1977, 1998) bold depictions with BHRA design and wide range of analysis gave us the courage to stick with the vertical wheel setup. Meanwhile, McKibben & Shook’s (1988) critical insights prepared us for the expected difficulties. Incorporating all the knowledge contributed by the past researchers, their wisdom and continuous solicitous guidance by our mentors, we delved into designing the final model for our Toroid Wear Tester Machine.