KfUPM 3D Face Shield Design Project Presentation the format is inserted below the hole report will talk about the summer training and what we have done so

KfUPM 3D Face Shield Design Project Presentation the format is inserted below the hole report will talk about the summer training and what we have done so far through this internship the internship was basically online so we first have a small discution on corona virus then get some information on literature review and finally we have worked on one design project and 2 case study (RCFA) Root Cause Failure Analysis.all what we have done inserted below the report should be more than 24 pages. and just follwo the bellow format The Report Guidelines
? The content of the report should be related to the assignments/projects, that you participated
in during your training.
? The introduction about the nature of the training (this time it was online) should be very
brief, in which you can give some idea how you have completed these 8 weeks of online
training.
? The main focus should be made on the work you have done such as in week 2 & 3 and then
mainly about RCFA and Design project.
? The students must demonstrate clearly their learning experience during the training such as,
“Type of projects or case studies he worked on”, “Problems and difficulties faced in them”,
solutions, suggestions and recommendations.
? Technical experience, knowledge gained and how he has utilized his knowledge of different
courses to solve the RCFA and design projects.
? Length of the report should be 20~25 pages.
The Report Format:
The report must be written in a formal way as you have studied in ENGL214. The report should be in
the following order;
?
?
?
?
?
Cover page (include title, your name, your ID#, advisor name, Instructor name, date)
Table of contents (main sections, subsections, headings, etc., with page numbers)
List of Tables, Figures, and illustrations, if any
Lists of symbols or abbreviations (if any)
Introduction (The introduction about the nature of the training (this time it was online)
should be very brief, in which you can give some idea how you have completed these 8
weeks of online training)
? The main body (starting from week#1 to week#8)
?
Description of the work conducted in Week#1
?
Description of the work conducted in Week#2& 3
?
Description of the work conducted from Week#4~8 (major portion
and describe in detail your RCFA and design projects)
? Conclusion (share your general experience of online summer training)
? References
? Appendices
?
Each of those items should start with a new page.
General guidelines;
? All the body text must be in Time New Roman Font. The size of the font should be 12. Titles
of chapters, sections, headings, etc. should be of size 16 and bold. Italic style shall not be used.
? The report must be TYPED and ORIGINAL. Figures and charts that are scanned or copied
should be appropriately referenced.
? The report must be in correct grammar and should be spell-checked.
? Report soft copy must be submitted online on BB by Tuesday, July 21st 7am.
Summer Training Report Grading:
Student Name :
I.D. No. :
Evaluate the report according to the following criteria
Earned
Mark
Evaluation criteria
Maximum
Mark
Content and organization:
? Table of Contents,
? Introduction
? Figure/Table citation
? Body of Report (design, analysis or case study)
? Conclusions,
? Recommendations,
? References
? Appendices
Quality & depth of data and discussion in RCFA & Design projects
? The quality of data in RCFA and design projects and their indepth explanation.
? Process of RCFA and design is well followed.
Grammar and Spelling :
? Quality of English writing, especially grammar and spellings
70
20
10
Total
100
Grade:
Pass:
? Excellent
X > 90
? Fail (Resubmit)
Comments (if any):
? Good
90>X>80
? Acceptable
80>X>70
Power Industry
Esso Longford
Heat Exchanger
Failure Root
Case Failure
Analysis
Prepared by:
• Abdullah AlHarbi
201594510
• Abdullah AlAjmi
201630500
• Abdullah AlBassam
201746550
What is RCFA?
RCFA background
• Processes
• Techniques
Table of contents
Background on heat exchangers
• Heat Exchanger types and their materials
• Heat exchanger failures
• Tubular Exchanger Manufacturers Association (TEMA) Codes
• Reliability of heat exchangers
Esso Longford gasplant explosion
• Reliability software
• Material operation
• Site overview
Our proposed heat exchanger
• Material selection using Ansys
• Solidworks
Recommendations
Conclusion
References
What is RCFA?
• Investigative techniques applied to the
determination of factors leading to an
initiating or original failure.
• Its main goal is to prevent this failure
from reoccurring.
RCFA proccess
1.
Problem definition.
2.
Develop clear understanding of the
situation.
3.
Propose temporary solutions.
4.
Modify/Edit.
5.
Confirm.
6.
Solutions and suggestions.
Useful RCFA techniques
[6] M., Says:, M., Says:, G., Says:, T., Says:, M., Says:, R., . . . *, N. (2020, June 16). 5-Why Examples [The Best and The Worst!]. Retrieved July 07, 2020, from

5-Why Examples [The Best and The Worst!]

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[7] Ishikawa Fishbone Diagram.svg. (n.d.). Retrieved July 07, 2020, from
https://ar.wikipedia.org/wiki/%D9%85%D9%84%D9%81%3AIshikawa_Fishbone_Diagram.svg
[8] The 80/20 Rule of DIY Airbnb Photography. (2019, May 22). Retrieved July 07, 2020, from https://overlooked2overbooked.com/the-80-20-rule-of-diyairbnb-photography/
Case study: Heat Exchanger Failures Objectives
Objective
1
2
3
4
Approach of achieving the objective
Research for the literature review for heat exchangers
and its material.
Searching for previous catastrophic events on heat
exchangers.
Use software and find old results if possible, for the
failure analysis.
Searching for expert recommendations on similar
problems and compare them with successful heat
exchangers.
Objectives
Heat
Exchanger
Failures Tasks
Tasks
By
Due Date
1.1 Materials and failure mechanisms.
1.2 Design and standards (codes) for materials.
1.3 Reliability Strategy.
Albassam
Alajmi
Alharbi
25 June, 2020
2.1 Engineering analysis of materials and failures.
2.2 Find old results for failure analysis.
2.3 Material software using CES or Solidworks.
Alharbi
Alajmi
Albassam
28 June, 2020
3
3.1 Do calculations based on the design.
3.2 Find stress distributions and other analysis.
3.3 Edit and modify based on previous data.
Alharbi
Albassam
Alajmi
30 June, 2020
4
4.1 Find the best solutions
4.2 Apply prevention methods to the problems
4.3 Conclude the case study.
Albassam
Alajmi
Alharbi
2 July, 2020
1
2
Heat Exchanger types and their materials:
Type
Components
Specifications
Tubes
low carbon steel, Admiralty, copper, copper-nickel, stainless
steel, Hastelloy, Inconel, or titanium.
Tube sheets
typically manufactured from the same material as tubes.
Shell
For economic reasons, steel is the most commonly used
material.
Bonnets and End Channels
typically fabricated or cast.
Baffles
Material selection must be compatible with the shell side fluid to
avoid failure as a result of corrosion
Inner and outer tubes
Carbon Steel and Copper
Plates
Stainless steel, Titanium, Titanium-Palladium, Nickel and
Hastelloy.
Gaskets
rubber gaskets
Frame
Austenitic stainless steel and Varnished common steel.
Connections
Connections formed by GAS-type socket sleeves made up of
carbon steel
Shell and tube heat exchangers.
Double pipe heat exchangers.
Plate heat exchangers.
[1] Materials & Construction. (n.d.). Retrieved June 24, 2020, from https://www.shelltube.com/Materials-and-Construction.html
Heat exchanger failures:
Type
Failure
Part
Mechanical
Metal erosion
U-bend & tube entrances
Steam or water hammer
Along the tube
Vibration
Along the tube
Thermal fatigue
U-bend
Freeze up
Along the tube
Thermal expansion
In the shell
Loss of cooling water
Along the tube
General corrossion
Along the tube
Pitting corrossion
Along the tube
Stress corrossion
Along the tube
Dezincification
Along the tube
Galvanic corrossion
Baffles
Crevice corrossion
Betweeen baffles and tubes
Condensate Grooving
Outerside of the U-bend
Combination of Mechanical & Chemically induced
corrosion
Erosion corrossion
Along the tube
Corrossion fatigue
U-bend
Scale, Mud, and Algae Funding
Dissolved solids (Sand, Iron, Silt)
Along the tube
Chemically induced corrosion

[2] Certikin. (n.d.). PLATE HEAT EXCHANGER USER AND MAINTENANCE MANUAL [Brochure]. Author. Retrieved from
https://genux.fluidra.com/get-document/heat_man_plate_heatexchanger-420.pdf
Tubular Exchanger Manufacturers Association
(TEMA) Codes
• TEMA is a trade association of leading manufacturers of shell and tube heat exchangers who
produced design standard
• TEMA code describes overall configuration of exchanger
• Code is 3 letters representing front head, shell and rear head
• Type AES is most common:
• A: channel + removable cover
• E: single pass shell
• S: floating head + backing device
[3] Certikin. (n.d.). PLATE HEAT EXCHANGER USER AND MAINTENANCE MANUAL [Brochure]. Author. Retrieved from
https://genux.fluidra.com/get-document/heat_man_plate_heatexchanger-420.pdf
TEMA :
• The TEMA Mechanical Standards are applicable to shell
and tube heat exchangers which do not exceed any of
the following criteria:
1. inside diameters of 100 in. (2540 mm)
2. product of nominal diameter, in. (mm) and design
pressure, psi (kPa) of 100,000 (1 7.5 x 1 06)
3. a design pressure of 3,000 psi (20684 kPa) The intent
of these parameters is to limit the maximum shell
wall thickness to approximately 3 in. (76 mm), and
the maximum stud diameter to approximately 4 in.
(102mm).
[3] Certikin. (n.d.). PLATE HEAT EXCHANGER USER AND MAINTENANCE MANUAL [Brochure]. Author. Retrieved from
https://genux.fluidra.com/get-document/heat_man_plate_heatexchanger-420.pdf
Reliability of heat exchanger:
• How to calculate Log mean temp
difference :
Reliability software in Esso Longford:
• Esso was a well-run facility, with a world-class safety management system and it still
experienced a major event.
• The framework Esso adopted was called Operations Integrity Management Framework
(OIMF). Exxon Company International had developed an 11 element management
system guidelines:
1. Management leadership, commitment and accountability;
2. Risk assessment and management;
3. Facilities design and construction;
4. Information/documentation;
5. Personnel and training;
6. Operations and maintenance;
7. Management of change;
8. Third party services;
9. Incident investigation and analysis;
10. Community awareness and emergency preparedness;
11. Operations integrity assessment and improvement.
[4] Hutchison, R. B., Boult, D. M., Pitbaldo, R. M., & Kenny, G. D. (n.d.). Lessons from the Longford Gas Explosion and Fire. Bow Tie Consulting. Retrieved June 29,
2020, from http://www.bowtieconsulting.com.au/pdfs/Lessons%20from%20the%20Longford%20Gas%20Explosion%20and%20Fire.pdf
Material operation in Esso Longford:
• A steel cylinder sprang a leak that let liquid hydrocarbon spill onto
the ground.
• A dribble at first, but then, over the course of the morning it
developed into a cascade.
• Ice formed on pipework that was normally too hot to touch.
• The metal casing of the heat exchanger was thereby rendered
extremely brittle.
• The fatal decision to introduce warm oil into the exchanger caused a
fracture followed by an escape of volatile gas and explosion.
[5] Hopkins, A. (2014). Lessons from Longford: The Esso Gas plant explosion. North Ryde, N.S.W.: CCH Australia Limited.
Esso Longford’s Site Overview
[5] Hopkins, A. (2014). Lessons from Longford: The Esso Gas plant explosion. North Ryde, N.S.W.: CCH Australia Limited.
Material in Shell and
Tube heat
exchangers
[3] Certikin. (n.d.). PLATE HEAT EXCHANGER USER AND MAINTENANCE MANUAL [Brochure]. Author. Retrieved from
https://genux.fluidra.com/get-document/heat_man_plate_heatexchanger-420.pdf
MATERIAL SELECTION (ANSYS)
Material Selection comparison
Material
Thermal
expansion
h_air(W/m^2*K)
h_hot
oilW/m^2*K)
h_cold
oil(W/m^2*K)
K(W/m.k)
Thickness of Thickness of
the shell
the tube
Shell Surface
Area
Tube Surface
Area
Hot oil surfce Cold oil surface
area
area
Rtotal
((m^2*)K/w)
1/Rtotal
q(W/m^2) Stress (Mpa)
Carbon steel
(ASTM A696)
0.002294
50
283.92
56.784
60.5
0.0125
0.003
4.00552725
0.080754571
4.00552725
0.061905031
1666.554034
0.0006
0.064804
0.000149
Carbon steel
(ASTM A696)
0.002294
50
283.92
56.784
60.5
0.0125
0.005
4.00552725
0.080754571
4.00552725
0.049338671
1900.180526
0.000526
0.056837
0.00013
Carbon steel
(ASTM A696)
0.002294
50
283.92
56.784
60.5
0.0125
0.01
4.00552725
0.080754571
4.00552725
0.017922771
3917.538116
0.000255
0.027568
6.32E-05
Stainless Steel (ASTM
316)
0.0030644
50
283.92
56.784
45
0.0125
0.003
4.00552725
0.080754571
4.00552725
0.061905031
1474.637239
0.000678
0.073238
0.000224
Stainless Steel (ASTM
316)
0.0030644
50
283.92
56.784
45
0.0125
0.005
4.00552725
0.080754571
4.00552725
0.049338671
1708.263731
0.000585
0.063222
0.000194
Stainless Steel (ASTM
316)
0.0030644
50
283.92
56.784
45
0.0125
0.01
4.00552725
0.080754571
4.00552725
0.017922771
3725.621321
0.000268
0.028988
8.88E-05
Copper Alloy (ASTM
B196)
0.0017296
50
283.92
56.784
413
0.0125
0.003
4.00552725
0.080754571
4.00552725
0.061905031
6031.575513
0.000166
0.017906
3.1E-05
Copper Alloy (ASTM
B196)
0.0017296
50
283.92
56.784
413
0.0125
0.005
4.00552725
0.080754571
4.00552725
0.049338671
6265.202004
0.00016
0.017238
2.98E-05
Copper Alloy (ASTM
B196)
0.0017296
50
283.92
56.784
413
0.0125
0.01
4.00552725
0.080754571
4.00552725
0.017922771
8282.559595
0.000121
0.013039
2.26E-05
Our Shell and
Tube parts
Final
assembly
Recommendations
• Based on our data and comparison shown previously it is proven that:
• Copper Alloy (ASTM B196) is the most suitable material to be used in the suggested
prototype in the tube and tube sheets.
• Stainless Steel (ASTM 316) should be in the shell.
• Bonnets and end channels should be casted.
• Finally, the baffles should be similar to the shell (Stainless Steel (ASTM 316).
• Gasplants should have its full personnel available at their times and in
cases of emergencies management should not be lenient in bringing in
replacements.
Conclusion
• In conclusion, failures could happen anywhere but how to avoid these
failures or how to take decision when it occurs is the most important
thing. In general, we were able to:
• Study the main issues of the heat exchangers thoroughly.
• Understand the characteristics of heat exchangers under severe
environments.
• Provide root cause failure analysis and material selection for heat exchangers.
• Suggest engineering lessons.
1.
Materials & Construction. (n.d.). Retrieved June 24, 2020,
from https://www.shelltube.com/Materials-andConstruction.html
2.
Alibaba. (n.d.). Retrieved June 24, 2020, from
https://wholesaler.alibaba.com/
3.
Certikin. (n.d.). PLATE HEAT EXCHANGER USER AND
MAINTENANCE MANUAL [Brochure]. Author. Retrieved from
https://genux.fluidra.com/getdocument/heat_man_plate_heatexchanger-420.pdf
4.
Hutchison, R. B., Boult, D. M., Pitbaldo, R. M., & Kenny, G. D.
(n.d.). Lessons from the Longford Gas Explosion and Fire. Bow
Tie Consulting. Retrieved June 29, 2020, from
http://www.bowtieconsulting.com.au/pdfs/Lessons%20from
%20the%20Longford%20Gas%20Explosion%20and%20Fire.p
df
5.
Hopkins, A. (2014). Lessons from Longford: The Esso Gas
plant explosion. North Ryde, N.S.W.: CCH Australia Limited.
6.
15, M., Says:, M., Says:, G., Says:, T., Says:, M., Says:, R., . . . *,
N. (2020, June 16). 5-Why Examples [The Best and The
Worst!]. Retrieved July 07, 2020, from

7.
Ishikawa Fishbone Diagram.svg. (n.d.). Retrieved July 07,
2020, from
https://ar.wikipedia.org/wiki/%D9%85%D9%84%D9%81%3AI
shikawa_Fishbone_Diagram.svg
8.
The 80/20 Rule of DIY Airbnb Photography. (2019, May 22).
Retrieved July 07, 2020, from
https://overlooked2overbooked.com/the-80-20-rule-of-diyairbnb-photography/
References
Design Project
Progress Report
3D Face Shield
Prepared by:
Abdullah AlHarbi
Abdullah AlBassam
Abdullah AlAjmi
Table of contents
1. Design Project Background
1. What is engineering design?
2. Engineering design process
2. Our suggested idea background
1. Objectives
2. Tasks
3. The importance of face shield
4. Advantages & Disadvantages of the common face shield available in the market
3. Our Initial Idea of The Face Shield Design
1. First idea
2. Second idea
3. Third idea
4. Design analysis
4. 3D Sketch
5. Force analysis
6. Stress analysis
7. 3D printing
8. Recommendations
9. Conclusion
10. References
What is Engineering
Design?
• The engineering design process is a series of
steps that engineers follow to find a solution
to a problem.
[1] Toor, U. U. (2020). ME399 – Engineering Design Process Week#4 (pp. 4-5). Dhahran: Blackboard.
Engineering
Design
process
1.
Toor, U. U. (2020). ME399 – Engineering Design Process Week#4 (pp. 4-5). Dhahran: Blackboard.
Objectives in order
to achieve our face
mask idea
Objectives
1
2
3
4
Approach of achieving the objective
The importance of the design and its background.
Looking into the initial design and its material.
Analyze the model with forces and stresses.
Finalizing the design project.
Objectives
1
2
Tasks
1.1 Importance of the project.
1.2 Study the market.
1.3 Our Value-add.
2.1 Initial design.
2.2. Compare between materials.
2.3 final design & material selection.
By
Due Date
Albassam
Alajmi
Alharbi
25 June, 2020
Alharbi
Alajmi
All with Doctor
29 June, 2020
Tasks to be working on:
3
3.1 Start & finish 3D modeling .
3.2 Do the drawing sheet.
3.3 Force and stress analysis.
Alharbi
Albassam
Alajmi
1 July, 2020
4
4.1 Printing
4.2 Assemble parts together
4.3 Final component to test it.
Albassam
Alajmi
Alharbi
3 July, 2020
? The Importance of Face Shield :
Nowadays, the Face shield is mandatory due to the current situation. Face shield provides
protection to the facial area and related mucous membranes. Hospitals, barbershops,
restaurants, and factories are the main customers.
? Overview of The Face Shield Market :
XPEL Face Shield
AO Safety Face Shield
Full Length Protection
Provides Unrestricted Visibility
Scratch Resistant
Crown protector is made of high-strength
thermoplastic material
The price is $6
The Price is $25
in the global market.
?Advantages & Disadvantages of the common face shield available in the market:
Advantages:
Disadvantages:
Protect a larger portion of the face
Relatively expensive
No impact on breath
Fogging
Easy to wear and take off
Not adjustable
? Our Value-add :
• Low cost :
The cost of our face shield is less than the average cost on the
market (10 SAR < 17 SAR) / piece. • Adjustable & Comfortable: • It will fit with all sizes (free size) . • Preventing fogging • Can be disinfected easily • It will be made from green material ? Our Initial Idea of The Face Shield Design: • It will consist of three main components: 1. PVC Foil 2. Elastic Band 3. Printed Frame of Face Shield Polyvinyl chloride (PVC) ? Advantages of Using PVC Foil: ? PVC can be recycled & reused : There are two common ways of recycling PVC, Mechanical and Chemical way. The concept of the mechanical recycle is grinding PVC into smaller particles that can be melted and remolded into same original product or into different new products. While the concept of the chemical recycle depends on chemical processes such as hydrolysis and pyrolysis the resulting products such as sodium chloride and calcium chloride are used to produce new PVC. ? Low cost ? Price of 100 (A4) Pieces of PVC is 20 SAR . ? Available in the market Elastic Band ? Advantages of Using Elastic Band: ? Comfortable & Adjustable ? Available in the market ? Low cost ? The price of 2.5m is 6SR PLA VS PETG • PLA is easier to 3D print and handle than PETG filament. • Both materials show minor shrinkage during cooling. • Also, both are user-friendly, but PETG filament is more durable, stronger, and can handle stronger impact. • PLA is less prone to scratching and surface damage. • PETG filament is generally more expensive than PLA. • PLA filament offers more way more variations. Printed Fram... Purchase answer to see full attachment