Forbes Marshall : Industrial Boiler

Redesigning the range of high-capacity steam boilers, focusing on ergonomics, usability, materials and aesthetics Implementable design with floor standing control panel Project Details Team: Manas Karambelkar Duration: 16 weeks Course : Degree project for Bachelor in Product Design Guides: Kunal Ghate, Vinay Mundada Client : Forbes Marshall Pvt Ltd Description The project was done as a degree project for Product Design course along with Forbes Marshall Pvt Ltd. Forbes Marshall has been building steam engineering and control instrumentation solutions that work for process industry. For this project the focus was on the high capacity boiler range 6 TPH (Tonnes per hour) to 13.5 TPH which are three pass fire tube boilers. These boilers are used in various manufacturing industries such as Packaged Food & Beverages, Brewing and Distilling, Pulp - Paper and Board, Sugar Refining, Pharmaceutical etc. Brief As the engineering parts and function was out of the scope of the project the design intervention was to be done in following areas. 1. Ergonomics and Usability : The product needs to be easy to use and maintain for the end users. Also, to some extent be made easier for manufacturing and assembly at the Forbes Marshall facilities. 2. Aesthetics and Branding : The company had recently launched a newly designed small scale boiler (4 TPH). The design of the High capacity boiler had to be made to complement this boiler to create an identity across all the ranges of boilers. Industrial products are not highly branded and should not get in the way of the functionality. So, the challenge was to make the branding as visible as possible but not intrusive. 3. Materials : The company was looking at material substitution for some of the non-engineering components  which could add to aesthetics, usability or make it easier to manufacture.
Existing 6.3 TPH boiler in assembly

Existing 6.3 TPH boiler in assembly

Process There was a detailed product, process and user study done. Some issues regarding usability were identified and worked out. The process was involving various people who were designers working within the company's R&D, engineers working in manufacturing, workers and foremen on the factory floor, part vendors and customers. Lot of time was spent on the factory floor and lot of brainstorming, sketching and 3D modelling done with the design team.
Usability and ergonomic study of the current product

Usability and ergonomic study of the current product

 
Exploring forms and mechanisms though sketches

Exploring forms and mechanisms though sketches

  Concepts & Delivery There were three different concepts which were designed. 1. Implementable 2. Mid-Futuristic 3. Futuristic 1. Implementable : This concept was looking at improvements in usability and aesthetics but staying within constraints of currently used manufacturing methods and material quantity. Same cost, more value and easy to use.
Implementable design with floor standing control panel

Implementable design with floor standing control panel

 
Implementable : Pressure gauge mounted at an angle helping in accurate reading

Implementable : Pressure gauge mounted at an angle helping in accurate reading

 
Implementable : Front view showing 3 part shielding plate made in FRP

Implementable : Front view showing 3 part shielding plate made in FRP

 
Implementable : Top view showing split platform for easy access to the valves mounted on top with anti-slip rubber mat on the floor

Implementable : Top view showing split platform for easy access to the valves mounted on top with anti-slip rubber mat on the floor

  2. Mid-Futuristic : This concept was with less constraints of cost and manufacturing but still had to be feasible. It is more like a premium model of the implementable concept with added features.
Mid-Futuristic : Front view

Mid-Futuristic : Front view

 
Mid-Futuristic : Enclosed accessories for better aesthetics. Suspended control panel that saves on floor space and could be oriented according to the customer requirement

Mid-Futuristic : Enclosed accessories for better aesthetics. Suspended control panel that saves on floor space and could be oriented according to the customer requirement

 
Mid-Futuristic : Pressure gauge mounted at an angle helping in accurate reading. A Single piece  shielding plate with large branding in FRP

Mid-Futuristic : Pressure gauge mounted at an angle helping in accurate reading. A Single piece shielding plate with large branding in FRP

 
Foldable railing saves space in transportation and reduced assembly on the customer end

Foldable railing saves space in transportation and reduces assembly on the customer end

  3. Futuristic : This was a fantasy concept to inspire something new and radical in the industry.
Futuristic : The boiler has digital gauges and controllers with wireless communication.

Futuristic : The boiler has digital gauges and controllers with wireless communication.

 
Futuristic : Front view showing rugged design language and a hinge mounted burner making it easier to clean the furnace.

Futuristic : Front view showing rugged design language and a hinge mounted burner making it easier to clean the furnace.

 
Futuristic : Hydraulic doors and additional platform on the side for easier access to the accessories

Futuristic : Hydraulic doors and additional platform on the side for easier access to the accessories

  A scaled model of the Mid-Futuristic design was made. Prototype   DSC06425


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