Iconic Oral B Brush designed by IDEO, of which Tim Brown (author) is CEO. Till this point, we learned about ‘design thinking process’, with empathetic thinking, Defining the problem statement, Ideate the concepts, build prototype, test and launch the product.
The designer who designed it, once went to near by sea shore, and found few of colorful brushes washed over beach! the design came to its end of the life cycle, most of the part of the brush was intact.
Designer can’t prevent people from doing what they want to do with its product they own, but that doesn’t excuse them from ignoring the larger system. Often in our enthusiasm for solving problem in front of us, we fail to see the problem that we create.
Change by Design
The book is all about all round thinking while designing a product/solution for a problem. IDEO is the company, which has brought the ‘design thinking’ concept to masses. and Auther himself is known as one of the founding members of this key concept.
Key Concept/ Take away
Ideas for #Leader
What is design thinking
Finding interdisciplinary team members
Putting people first
Inspiring the birth of great ideas
Ideas for #Process
Look : Look at inspiration, ideation, and implementation together to become great at design thinking.
Prototype : Build the prototype of your idea and begin testing as early as possible to help you encompass all areas of innovation at once.
Storytelling : If you want to make your great new idea stick, use storytelling.
About Author
Tim Brown : CEO of IDEO
Tim is leading IDEO, and key person to bring ‘Design Thinking’
He has published many books/articles for this topic including for innovation.
Process on ‘how to innovate’ is explained simply, with three step approach. Innovation is an ongoing activity, its not an on/off like activity. One has to be mindful of his surrounding, get inspiration and how quickly we can bring idea to life thru rapid prototyping. Few example like complex product like google glasses the prototype was done in 30 min!
I Understand role of Empathy in design thinking, but the insight I got from this book is, empathy without action is of no use, what we need to do is act quicky and convert idea into reality by rapid prototyping.
How one preheats they boiler feed water? We have two options,
Via economiser, mounted on exhaust of boiler, and heating incoming feed water by absorbing lost heat in flue gases
Via Deareator tank, adding steam to deareator and heating the water temperature. Though the purpose of deareator is as name suggest remove the “oxygen” from the water, by heating it. Nevertheless it also increases the temperature of water in this process.
Let’s talk about economiser
Now that’s the question, one should not ask, if possible, one should always use economiser. It generally speaking will increase boiler efficiency by 3-5 percentage points.
It also helps reduce the thermal stress on boiler as a whole.
Then why this question?
Challenges with economisers are few, apart from how much heat we are recovering vs how much expenditure we are doing in is installation, maintenance and qualification.
Assuming the economics works well, the next question is if you absorb too much heat, and condensation happens, it will lead to sulphur corrosion, distorting not only boiler but also chimney in long run.
Criteria for designing economiser from user perspective
Define maximum hot water temperature we expect out of economiser, this has to be above sulphur due point
Define maximum pressure drop allowed. As more pressure drop will add more duty to the Blower, adding to running energy cost
Acid Dewpoint Corrosion
Criteria for design from Designer’s perspective
Configuration of path, with multiple branches to make water flow, it helps get maximum efficiency but also adds to pressure drop and duty on feed pump
Profile of fins for heat exchanger, some profiles of fins, for example serrated fins, has huge heat transfer to area ratio, and are highly efficient, but also adds to pressure drop on air side, and blower duty increases accordingly.
Number of passes of hot flue gases, this ensures more residential time for the flue gas, so that we can extract more heat, however, this will also cost us more pressure drop and added duty to the blower.
Minimum feed water temperature and maximum outlet temperature, both factors are important to ensure we get better efficiency but also to ensure we have less issues with corrosion (oxygen pitting
Typical failure reasons
Typically in boiler, the flue gas is mostly utilised to super heat the steam, and then passed to economiser, in such cases, The temperature differentials between the flue gas and water are quite low. To maximize heat transfer, water temperatures at the end of the economizer run should be very close to the saturation temperature. If the temperature difference is very low, then it some time can lead to steaming in economiser. Steaming not only reduces the efficiency drastically but also lead to knocking and failure of weld during operation due to thermal impact.
Second reason for failure could be quenching effect. This happens, when boiler is stand by mode, that is steam is not consumed. Water in economiser reduces drastically, and sudden surge in demand, make feed pump, pump cold water to economiser, leading to thermal stresses, even if the delta of water differential is low, this will lead to failure after some time. This issue can be over come by losing some water in boiler itself via intermediate blow down, small water circulation in economiser helps avoid such quenching issues.
In office someone told me, lets not spend (tone was ‘waste’) time in making P&ID, as our machine has no piping! an I was like … confused on matching the description of P&ID with need of P&ID. and hence this article.
I just went back to basis, and tried to find out whats the ‘dictionary’ meaning first.
ISA 5.4 Says, This standard establishes minimum required information and identifies additional optional information for a loop diagram for an individual instrumentation loop. This loop is typically part of a process depicted on the class of engineering drawings referred to as Piping and Instrument Drawings (P&IDs).
EN ISO 1068 Says, a piping and instrument diagram (P & ID)
Document on ISA Website , refer The process and instrumentation diagram (“P&ID” as it often called) represents a document that can take on many different forms .
IS 3232: Says, RECOMMENDATIONS‘ ON GRAPHICAL SYMBOLS FOR PROCESS FLOW DIAGRAMS, PIPING AND INSTRUMENTATION DIAGRAMS
South Austria Water Technical Standard TS 112 : Process and Instrumentation Diagrams (P&ID)
So, is it Piping of Process diagram? What we understand?
The challenge, limiting it to piping application, user can ignore its advantage on discrete machines, where there is no piping (or less of it), but its highly automated.
To answer this question, we need to see what the diagram help us with.
It help us with
Understanding the design philosophy.
Understanding of process flow (energy and mass flow)
Process Control parameter, loops, interlocks
Economics of system, process optimization
HAZOP Study
Unit operation, interlinking between plants and machines.
It will be more appropriate to consider P&ID and Process & Instrument Diagram, which shows following but not limited.
Orbital welding in Sanitary application is extension to tungsten inert gas (TIG/TGAW) welding. This type of welding is default in piping, which the application demands Sanitary or super clean application, where cleaning is done with CIP/SIP.
The pharmaceutical industry currently uses orbital GTAW/TIG welding almost exclusively. This produces welds of high quality with very low rejection percentages; these joints possess high strength, high purity meta, and good surface finish.
Orbital welding is the controlled rotation of components within a fixed support, while an adjustable, non-consumable tungsten electrode attached to a guide moves (or “orbits”) the joint. The electrode, the arc, the area surrounding the weld, and tube interior are protected by a shield of inert gas—usually argon—with a purity of 99.995/99.999%
Virtually all the metal alloys employed in the pipeline fabrication sector can be welded and since the process is carried out in an inert atmosphere it produces results that are extremely clean, oxide free and without spatter
Its completely automated process and hence needed precision when preparing the face and edges before welding.
Following mind map will help you understand variable in Orbital welding. Please Explore. Will add more information shortly.
As we know, the out put from these industry are directly consumed by end user, and it impact either health value or patients safety! Its prime importance that the metal used in these industry ensures no impact on quality of products and also ensures minimum maintenance.
Many time, manufacturer prefer to take different batches of products in same equipment, and this leads to one more challenge of cleanability. and when one like to be equally sure, that no residual is passing to next batch, its prime important that the metal should not react with any chemical cleaning agents!
Stainless steels are uniquely qualified not only because of their long service life, availability and fabricability, but also because they are non-corroding, non-contaminant, they can be polished to very smooth finishes, they are strong and rigid, they can withstand heat and chemical sterilization treatments, and they are easily welded.
In such industry, following metals are preliminary used.
304 and 316 stainless steels and their L grades
Austenitic stainless steels with higher Mo content
Duplex stainless steels group
Superaustenitics in particular “6Mo”
Ni, Cr, Mo family commonly called the “Alloy C family”
Cobalt based alloys with high corrosion and wear-resistance
Titanium alloys, referred as chemically pure (CP)
Following table shows chemistry of typical Stainless steel used in industry
Ergonomics design for Push Trolley (System on wheel, managed by Pushing)
As per HSE, Pushing and pulling of loads is a way to avoid manual lifting and carrying of objects such as by putting the load on a trolley.
Why its important to study? and even design?
Statistics can be seen below that give you an idea of how important it is to eliminate or reduce pushing and pulling risk factors.
11% of manual handling – related RIDDOR accidents investigated by HSE involved pushing and pulling.
The most frequently reported site of injury was the back muscle injury (44%).
Followed by the upper limbs (shoulder, arms, wrist and hand) accounted for 28.6%.
12% more accidents involved pulling than pushing (where the activity could be identified within the reports).
61% of accidents involved pushing and pulling objects that were not supported on wheels (e.g. bales, desks etc.)
35% of pushing and pulling accidents involved wheeled objects!
IS there any Regulation?
Yes, we have to comply with the risk assessment requirements set out in the Management of Health and Safety at Work Regulations 1999 as well as the requirement in the Manual Handling Operations Regulations 1992 (as amended) (MHOR) to carry out a risk assessment on manual handling tasks.
So, Tell me about design now 🙂
Following are the quick tips, then my next post will talk more in details.
Choose PUSHING a load instead of PULLING it whenever possible
Place your hands at the correct height.
Followings are weight (push or pull) to stop the load! will cover this in next post.
So, we have covered Destructive testing in my last post, now something on Non-destructive testing.
There are Numerous Non-Destructive tests used to evaluate the base metal to be joined as well as completed welds. However these all NDT shares several common elements, these essential elements are summarized below:
o A Source of Probing energy or Medium
o A Discontinuity must cause change or alteration of probing energy
o A means of detecting this change
o A means of indicating this change
o A means of observing or recording this indication so that an interpretation can made.
Over the years Numerous Non-Destructive Testing Methods have been developed, each one has associated with its various advantage & Limitations.
Followings are the Noted NDT Methods o Penetrant Test (PT)
o Magnetic Particle Test (MT)
o Radiographic Test (RT) o Ultrasonic Test (UT) o Eddy Current Test (ET) 1. Penetrant Testing (PT)
Liquid penetration inspection is a method that is used to reveal surface breaking flaws by bleedout of a colored or fluorescent dye from the flaw. The technique is based on the ability of a liquid to be drawn into a “clean” surface breaking flaw by capillary action. After a period of time called the “dwell,” excess surface
penetrant is removed and a developer applied.This acts as a “blotter.” It draws the penetrant from the flaw to reveal its presence. Colored (contrast) penetrants require good white light while fluorescent penetrants need to be used in darkened conditions with an ultraviolet “black light”.
Detection of Defect using Black-light
Table for Dwell time
2. Magnetic Testing (MT)
Magnetic particle inspection is a nondestructive testing method used for defect detection. MPI is a fast and relatively easy to apply and part surface preparation is not as critical as it is for some other NDT methods. These characteristics make MPI one of the most widely utilized nondestructive testing methods.
MPI uses magnetic fields and small magnetic particles, such as iron filings to detect flaws in components. The only requirement from an inspectability standpoint is that the component being inspected must be made of a ferromagnetic material such iron, nickel, cobalt, or some of their alloys. Ferromagnetic materials are materials that can be magnetized to a level that will allow the inspection to be effective. The method is used to inspect a variety of product forms such as castings, forgings, and weldments. Many different industries use magnetic particle inspection for determining a component’s fitness-for-use. Some examples of industries that use magnetic particle inspection are the structural steel, automotive, petrochemical, power generation, and aerospace industries. Underwater inspection is another area where magnetic particle inspection may be used to test items such as offshore structures and underwater pipelines
Electromagnetic Yoke Detail Diagram
Electromagnetic Yoke Application
Application of Dry Powder
The Magnetic Field Intensity Measure
Defect Detection in Weld Using MPI (Dry Powder)
Before and after Inspection MPI Detection
3. Radiographic Testing Covered in detail in my older post
4. Ultrasonic Testing (UT)
Ultrasonic Testing (UT) uses high frequency sound energy to conduct examinations and make measurements. Ultrasonic inspection can be used for flaw detection/evaluation, dimensional measurements, material characterization, and more. To illustrate the general inspection principle, a typical pulse/echo inspection configuration as illustrated below will be used.
A typical UT inspection system consists of several functional units, such as the pulser/receiver, transducer, and display devices. A pulser/receiver is an electronic device that can produce high voltage electrical pulse. Driven by the pulser, the transducer generates high frequency ultrasonic energy. The sound energy is introduced and propagates through the materials in the form of waves. When there is a discontinuity (such as a crack) in the wave path, part of the energy will be reflected back from the flaw surface. The reflected wave signal is transformed into electrical signal by the transducer and is displayed on a screen. In the applet below, the reflected signal strength is displayed versus the time from signal generation to when a echo was received. Signal travel time can be directly related to the distance that the signal traveled. From the signal, information about the reflector location, size, orientation and other features can sometimes be gained.
cross-section of the Probe
Beam spread occurs because the vibrating particle of the material (through which the wave is traveling) do not always transfer all of their energy in the direction of wave propagation. Recall that waves propagate through that transfer of energy from one particle to another in the medium. If the particles are not directly aligned in the direction of wave propagation, some of the energy will get transferred off at an angle. (Picture what happens when one ball hits another second ball slightly off center). In the near field constructive and destructive wave interference fill the sound field with fluctuation. At the start of the far field, however, the beam strength is always greatest at the center of the beam and diminishes as it spreads outward.
