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Increasing Throughput through Condensate Pump

May 29, 2018

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    QAI India Limited. All rights reserved.

    Increasing

    Throughput

    through

    CondensatePump

    INDIA | USA | UK | CHINA | MALAYSIA |SINGAPORE

    A presentation byQAI

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    Innovation Case Study: Steam Condensate Pump Product Design

    Innovation Case Study: Steam Condensate Pump Product Design

    Project Objective: To find product design specific technological solutions to increase the discharge rate

    of Steam Condensate Pump

    Process: Steam Condensate Management

    Organization and Industry: Leading international supplier of pumps

    Case Background:As an energy saving practice, many organizations that use steam for process control

    or heating take considerable effort to recover the subsequent hot condensate. This condensate (hotwater) is returned to the boiler, where it is heated and pressurized to the system requirements. When

    condensate leaves the steam trap, it contains approximately 20% of the heat energy transferred in the

    boiler to generate steam. Vertical displacement pressure powered pumps are a popular technical system

    used to pump the condensate back to the boiler.

    Figure, below shows the internals and workings of a vertical displacement pressure powered pump.

    Figure: How the Pressure Powered Pump (PPP) Works

    One of the challenges faced by manufacturers of PPPs is that while the pump is in the filling stroke, no

    condensate is being pumped to the boiler. Adding multiple PPPs leads to increased utilization of the space

    which is not available at sites since PPPs are typically installed in low space areas where manual

    intervention is kept at the minimum and the environmental conditions are also harsher

    The current project has been undertaken to find out technological solutions to increase the discharge rate

    of the vertical displacement PPP.

    Confidential 2008 QAI Asia 1

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    Innovation Case Study: Steam Condensate Pump Product Design

    Challenges facing the organization

    The team lacked a structured process for guiding the thinking process to generate innovative product

    design solutions that are cost-effective and implementable.

    Past attempts at product design were unable to meet all criteria set by management: cost effective, ease

    of implementation, and increased throughput rate. The ideas generated by the team were either leading

    to increased complexity of the product or increased costs.

    Project Success criteria defined by Management

    Management was exploring a structured approach to innovation that was low on complexity without

    compromising the rigor and effectiveness. The following criteria were defined for evaluation of the ideas

    1. Cost of implementation should be low

    2. Ease of Implementation

    3. Maintainability in the long run should be easy

    4. Solution should result in a high satisfaction score from the user of the pump.

    QAIs Consulting Approach

    The project was executed in the three phases

    shown in the figure.

    1. Information Gathering

    a) The primary objective of Information

    Gathering phase is to

    1. Understand the Main

    Parameters of Value from a

    customer perspective

    i. Main Parameters of Value (MPV) are those attributes for product or service that

    will have the greatest significance in the customers purchasing decision.

    ii. Innovation requires a precise understanding of value: the who, what, when,

    where, how, and why of the customers need. It then means getting that value

    to them without complexity creeping in.

    Confidential 2008 QAI Asia 2

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    Innovation Case Study: Steam Condensate Pump Product Design

    2. Study the solutions proffered by the industry to satisfy those parameters by doing prior

    art search and

    3. Obtain insights into the under-served opportunities.

    For the steam condensate project the study obtained detailed information related to the pump,

    its components, its working environment and also all advancements made by the industry till

    date. This study proved valuable in revealing that the industry had inadvertently got caught in

    certain psychological traps with respect to the possible solutions directions.

    2. Analysis

    a) The primary objective ofAnalysis is to obtain

    insights from the

    Information Gathering

    phase on under-served

    Main Parameters of

    Value.

    b) It further involves a rigorous component level analysis

    of the product and the analysis of the environmental

    conditions to determine the opportunities for

    improvement in product design.

    c) The images show a snapshot of the different product

    analysis such as Functional analysis, and root-conflict

    analysis for the steam condensate components.

    3. Concept Development

    a) The next step in this project was to combine

    several ideas into workable concepts and to

    evaluate the concepts against the evaluation

    criteria of the customer (sample snapshot shown

    in figure alongside).

    b) Each of the concepts were assessed on a scale of

    1 to 5 where 1 stood for Very less ability to meet

    Confidential 2008 QAI Asia 3

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    Innovation Case Study: Steam Condensate Pump Product Design

    the Criteria and 5 stands for Very strong ability to meet the Criteria.

    4. Deployment of the recommended changes

    a) The organization has decided to deploy one of the concepts in the immediate future.

    b) A patent is also being filed for this concept.

    Benefits Obtained

    Evaluation Parameter Before After

    Patentable Concepts - 4

    Patents Filed - 1

    Pump Discharge Rate 100 200

    (Indexed) (Index value) (Index value)

    Confidential 2008 QAI Asia 4

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    QAI India Limited. All rights reserved.

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    USA

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    CHINA

    MALAYSIA

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    QAI

    All rights reserved. No part of this document may be reproduced or distributed in any form or byany means, or stored in a database or retrieval system, without prior written permission of QAI

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