Introduction to Engineering

Design
NASIR OSMAN
G.M (Design & Engineering)
Retired NTDCL
INTRODUCTION OF SPEAKER
• B.SC Electrical Engg Uet Lahore 1982
• MBA Technology Management
Canada
• Diploma in Finance Canada
• MCSE Microsoft certification
• CCNP Cisco Certification

2 Notes of S. Takagaki, H. P. Huang, S. Ramaswamy Introduction to Engineering Design

INTRODUCTION OF SPEAKER
• Initiative for the introduction of static
energy meters in Pakistan
• Initiative for development of specification
for low loss energy efficient Distribution
Transformer
• Intiative for the introduction of ABC cables
• Introduction of Twin Bundled 132 kV
Transmission line
• 3 Lead the SCDA project in Pakistan
Notes of S. Takagaki, H. P. Huang, S. Ramaswamy Introduction to Engineering Design
 Foundational Questions
What is an engineer?
What is engineering design?
Difference between engineering analysis and engineering design
What is the difference between product and process design?
What is the context of the design process?
Engineering design vs. design in other academic disciplines?
Why design?
 What is engineering design?
• Engineering design is the set of decision-making processes
and activities used determine the form of an object given the
functions desired by the customer.
• Engineering design is the process of devising a system,
component, or process to meet desired needs. It is a decision-
making process (often iterative), in which the basic science
and mathematics and engineering sciences are applied to
convert resources optimally to meet a stated objective. Among
the fundamental elements of the design process are the
establishment of objectives and criteria, synthesis, analysis,
construction, testing and evaluation.
 Human creativity
Engineering as a “Thinking-Making” Activity
The use of technology to make products and systems
for societal benefit.
 Historical Questions
What role of engineers in history?
Irrigation and farming equipment, dam projects, water and wind mills building construction,
the Pyramids, the Great Wall, Leonardo’s contraptions, the printing press, the Wright brothers’
aircraft, fermented beverages, nuclear power, the Space Shuttle, Tacoma Narrows Bridge,
electric appliances, petroleum products, pharmaceuticals.

When did the engineering disciplines begin?

3000 BC Civil
1000 BC Military
AD 1700 Mechanical
AD 1800 Materials
Agricultural
Electrical
AD 1900 Chemical
Aerospace
AD 1950 Computer, Nuclear, Biochemical
Biomedical
[ Holtzapple, M. T., Reece, W. D. (2005) ]
 Product Realization Process
(PRP)
• Engineering design
• Industrial design
• Production planning
• Manufacturing
• Distribution
• Sales
• Marketing
• Service
• Disposal
 Problem solution
Engineering as Problem Solving

Problem identification
Synthesis Orderly stepwise approach
Analysis
Qualitative/general
Application  quantitative/detailed

Comprehension

Solution
 Process of Engineering

Think Think Math Politics

Analysis
Sketch Sketch Physics Law
Make Make
Chemistry
Show Show Ethics
Use Use Biology
Environmental

Economy
Process of Engineering
Need

Analysis of Problem

Statement of Problem Brainstorming

Rule : There are
Conceptual Design
no stupid ideas
in a brainstorm
Selected Schemes

Embodiment of Schemes

Detailing

Working drawings, etc..

 PRODUCT DESIGN
• What is a product or process?
• Prototype sample
• Development According to Reference Standrds or Need
of the market or target market better product
• Opertaional efficiency
• Total innovative approach
• Re designing Enhanced feature
• To Get More Market share may be monopoly for some
time
• Profit Earning
Development Cycle
 Examples in Distribution Transformers
Materials
- Iron Core
- Copper
- Paper
-OIL
-Tank
- Tubular or Corriguated
Insulators
Hardware

EFFECTIVE DESIGN WILL LEAD TO BETTER

PERFORMANCETe
Technical Advantage
Profit Earning -
 Energy Efficient Transformers
• Energy Efficient
– Smart less ,less energy loss ,same or more
efficiency
– For transformers
– Iron Losses Fixed Losses no dependency on
load variation
– Copper Losses variable
– Cooling Mechnism
– Tank design
15 Notes of S. Takagaki, H. P. Huang, S. Ramaswamy Introduction to Engineering Design
 Product Design
• New products are critical for corporate
prosperity
• Approximately 33% of revenues come
from products that did not sell 5 years ago
• Successful new products are profitable
– Median achieve 33% ROI or better
– Median have payback of 2 years or less
– Median achieve market share of 35%

• Significant R&D expenditures and

investment
 Energy Efficient Transformers
• Need for Efficient Design
• Just new design was introduced by
targeting 30% Reduction in Iron and
Copper losses
• Loss capitalization provided incentive to
manufacturer for better price ranking
award with its time value money based
Return on Investment

17 Notes of S. Takagaki, H. P. Huang, S. Ramaswamy Introduction to Engineering Design

 Engineering Design vs Engineering Analysis

• Engineering analysis: Predicted behavior is the solution

to an analysis problem
– Formulating
– Solving
– Checking

• Engineering design:
– Formulating
– Generating
– Analyzing
– Evaluating
Design Step
 Issues in Product design
Utility and cost
Single and multi-functionality
Batch or mass production
Patents
Aesthetics
Integrity of product (wholeness)
Whole life-cycle planning
Health effects and safety
Recycling and disposal
End of product life and replacement issues
Failure modes
Effects on society
 Product Approval Process
Procurement
• Technical Evaluation
• Compliance of the offered product
principal Technical Parameters' to the
offered schedule of technical Data
• Principal Technical Parameters
– Impulse level
– Short circuit level
– Temprature Rise

21 Notes of S. Takagaki, H. P. Huang, S. Ramaswamy Introduction to Engineering Design

 Technical Compliance
• Power Frequency
• Any special Application test
• Set of test be verified from the provided
Type test report
• With the same Type and Designation as
tested
• Its determination of limit range of
verfication
22 Notes of S. Takagaki, H. P. Huang, S. Ramaswamy Introduction to Engineering Design
 Technical Specification
• NTDC Technical specification for all the
items should be firm and final .
• The master copy of which with initial be
kept as master copy with design NTDC
• Copies of all such specification be hoisted
at NTDC web site as general guide lines
not for tendering purpose
• Design NTDC will issue the updated
specification for each tender
 Technical Specification
• Technical Requirement & Specification
• Technical requirement should not override the
specification
• Any explicit technical requirement be made as an
amendment in specification
• For any technical clarification the reference standard in
specification like IEC OR ANSI what ever will be
applied in the latest version of the standard which was
available at the time of bid issued
• For any un specified item PD (Product Description) be
made while defining the features of the product
required to be procured
 TYPE TESTING & DESIGN
VALIDATION. Technical
•
Specification
An amended clause in the bidding document be in corporate

– If the offered material is not type tested the bidder will name the
lab to perform type testing in any of the ILAC member lab and
ISO 17025 qualified duly witnessed by the representative of
any STL member NTDC and representative .

– If the material is already tested in any of the STL member lab

under the reference standard of NTDC specification ,without
witnessing of NTDC representative the same should be
acceptable to the extent that at the time of inspection the visiting
inspector will determine the variance of previously conducted
type test with sample test and its limit should be within IEC
standard .May a temperature rise test over and above sample
test will be sufficient to determine quality
 TYPE TESTING & DESIGN
VALIDATION
• A clear understanding of the product ordering code type and designation is
required to be understood by design department
• As particularly products of european origin are continous in
development and they do change the code with minor changes with
subscripts
• Such changes do not be stressed for re type testing
• European products produced and tested in europe started
manufacturing china or any other country does not qualified for
retype testing (Change of Origin of Manufacturing) Its similarity and
compliance be determined as per indvidual components at the time
of then type testing and issuence of drawing

• NTDC specifcation should in corporate such information and write down

the methdology of quality assurence through non destructive tests and
measurement of variance as per IEC standard during inspection
 EQUIPMENT TESTING

• TYPE TESTING
• DESIGN VALIDATION OF THE OFFERED
PROTOTYPE SAMPLE
• NTDC SPECIFICATION ,IEC IEEE OR ANSI
• ROUTINE TESTING/FAT/SAMPLE
TESTING
• IN FACTORY TESTING GENERALLY ON
PRODUCTION LINE
• FAT FACTORY ACCEPTANCE TESTS
• SAMPLE TESTS
» ON SELECTED SAMPLE FROM OFFERED LOT
 TYPE TESTING REPORTING
• TYPE TEST CERTIFICATION
• ALL TESTS PERFORMED ON OFFERED
SAMPLE
• TYPE TEST REPORT
• TEST CONDUCTED ON AS PER REQUIREMENT
OF THE MANUFACTURER OR PURCHASER
• INSPECTION REPORT
• TESTS WITNESSED BY THE ACREDITED LAB
IN ISO 17025 CERTIFIED LABS
 SHORT CIRCUIT LIASON
(STL)
• INTERNATIONAL COLLABORATION OF
TESTING ORGANIZATIONS
• EQUIPMENT FOR ABOVE 1000 V FOR TYPE
TESTS INCLUDE SHORT CIRCUIT AND
DIELECTRIC TYPE TESTS
• QUALITY ASSURENCE
• PRECISION
• UNIFORM REPORTING
• INSPECTION
• REPORTING
 ASSOCIATIONS
• PEHLA
• ASOCIATION OF MANUFACTURER LABS
• INTERTEK
• ASTA
 NTDC REQUIREMENT
• TESTING FROM STL MEMBER LABS
• KEMA HOLLAND,CESI ITALY ,KERI KOREA CREEPI
JAPAN
• INSPECTION REPORTS ACCEPTED
• PPREVIOUSELY
• ILAC /APLAC ACREDITED ISO 17025 CERTIFIED
LABS WITNESSED BY STL MEMBER LAB
REPRESENTTAIVE
• INSPECTION REPORTSHOULD
CONTINUE BE ACCEPTED
• TRANSFORMERS ,CIRCUIT BREAKERS
,DISCONNECTORS WHERAS PREVIOUSELY TYPE
TEST CONDUCTED INDEPENDENTLY ON
ACREDITED LAB SHOULD BE ACCEPTED
• ALREADY TYPE TESTED WITNESSED BY NTDC
REPORTS SHOULD BE ACCEPTED
 NTDC TYPE TESTING POLICY
ADDITION
• NTDC ADOPT OPEN POLICY FOR ALL INCOMMING
FOREIGN MANUFACTURER TO OFFER MATERIAL
FOR WITNESSING TYPE TESTING IRRESPECTIVE
OF PURCHASE ORDERS
• ONLY MANUFACTURER SHOULD OFFER TYPE
TESTED MATERIAL FROM INDEPENDENT
ACREDITED LABS FOR PARTICIPATION IN BID OR
FOR ASSESSMENT OF REQUIREMENT BEFORE
PARTICIPATING IN BID
• FOR MATERIAL LOCALLY TYPE TESTED EVERY 5
YEAR BE ENHANCED AFTER 20 YEARS TO 10
YEARS FREQUENCY
 NTDC REQUIREMENT
• FOR HIGH VOLTAGE TRANSFORMER
OF 220 KV AND 500 KV
• HIGH COST MAY REQUIRE COMPLETE THIRD
PARTY CERTIFICATION FOR FIRST
PROCUREMENT FROM NEW ENTRANT
• WITH VALIDATION OF SHORT CIRCUIT
CALCULATIONS
• FAT WILL BE WITNESSED BY NTDC
• osman57@gmail.com

36 Notes of S. Takagaki, H. P. Huang, S. Ramaswamy Introduction to Engineering Design