CAVTnRIDGE
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Listening GPS applications Spaceelevators Advantages of a newpump A guidedtour Reading Spaceelevators Otis lifttechnology Pile foundations
Describingtechnical functionsand applications Explaininghowtechnology works Emphasising technical advantages Simplifyingand illustrating technicalexplanations
Wordsstemmingfrom use allow, enable,permit, ensure, prevent Verbsto describemovement Verbsand adjectives to describe advantages Adverbsfor addingemphasis Phrasesfor simplifying and rephrasing
Describingspecific materials materials Categorising SpeciÍyingand describing properties Discussingqualityissues
Listening Commonmaterials audit An environmental Categoriesof materials tools Specialised made made of, comprise, of, consist watches High-performance from,mode out of Reading Propertiesof materials Materialsrecycling Phrasesfor describingrequirements Regenerative brakes CompoundsoÍresistant Kevlar Adverbsof degree
Describingcomponent shapesand features Explainingand assessing manufacturing techniques jointingand Explaining fixingtechniques Describingpositionsof assembledcomponents
Shapesand 3D features Wordsto describemachining Phrasesfor describingsuitability Verbsand nounsto describejoints and fixings of position Prepositions
Listening A projectbriefing Electricalplugsand sockets Metalfabrication UHP waterjetcutting Optionsfor fixing Clusterballooning Reading Cuttingoperations Flowwaterjettechnology Jointsand fixings Theflyinggardenchair
Workingwithdrawings Discussingdimensionsand precision Describingdesignphases and procedures Resolvingdesignproblems
Viewson technicaldrawings Phrasesrelatedto scole Phrasesrelatedto tolerance length, width, thickness, etc. Drawingtypesand versions Verbsfor describingstagesof a designprocess Verbsand nounsfor describing designproblems
Listening A drawingquery Scale A floordesign Designprocedures Revisinga detail Reading Superflatfloors Oueriesand instructions
Describingtypesof technicalproblem Assessingand interpreting faults Describingthe causesof faults Discussingrepairsand maintenance
Verbsand adjectives for describing Listening A racingcar test session technicalproblems Testsessionproblems Wordsfor describingfaultsand Technical help{ine theirseverity Tyrepressureproblems Phrasesfor describingcertainty/ A maintenance check uncertainty Reading Adjectiveswith prefixesfor Air TransatFlight236 describingtechnicalproblems Verbsfor describingrepairsand maintenance
Contents
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Discussing technical requirements ideasand Suggesting solutions Assessingfeasibility Describingimprovements and redesigns
Phrasesfor referringto issues Phrasesfor referringto quantity and extent Phrasesfor suggesting solutions and alternatives ldiomsto describefeasibility Verbswithre...to describe modifications ldiomsto describeredesigning
Listening Simulatorrequirements and effects Liftingoptions Hole requirements and forming A projectbriefing Reading Mammothproblem
Describinghealthand safetyprecautions Emphasising the importanceof precautions Discussingregulations and standards Workingwithwritten instructions and notices
Typesof industrialhazards Typesof protectiveequipment Phrasesfor emphasising importance Termsto describeregulations Commonlanguageon safetynotices Languagestylein written instructions
Listening A safetymeeting Hazardanalysis Liveline precautions Safetytraining Oral instructions Reading Livelinemaintenance Helicoptersafetyon oil platforms
Describingautomated systems Referringto measurable parameters Discussingreadingsand trends Givingapproximatefigures
Wordsto describeautomated systems Wordsto describemeasurable parameters Wordsto describefluctuations Wordsand phrasesfor approximating numbers
Listening Intelligent buildingsand automation Monitoringand controlsystems Electricitydemandand supply problems Pumpedstoragehydroelectricpower Internalreviews Reading Industrialprocessmonitoring Dynamicdemandcontrols
Explainingtestsand experiments Exchanging viewson predictionsand theories Comparingresultswith expectations Discussingcausesand effects
Wordsto describetest types Wordsand phrasesfor stating assumptions Wordsand phrasesfor agreeingand disagreeing Phrasesfor comparingexpectations and results Wordsfor linkingcausesand effects
Listening Vehicledesignand testing Water rockets Air drop problems Moon landings Reading A rocketcompetition Chickencannon
Discussingperformance and suitability Describingphysicalforces Discussingrelative performance Describingcapabilitiesand limitations
Adjectives for describingsuitability and performance Wordsto describetypes of forces foctof criteria, criterion, consideration Wordsand phrasesto describe degreesof difference Wordsto describecapabilitiesand limits
Listening Windturbinetowers Tallstructures TCV world speed record The storyof John Paul Stapp Reading Windturbinesfactfile Solar towers Transportalternatives The Sonrc Wind tests The rocketsled proposal
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Contents
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Describingtechnicalfunctions I
I
andapplicatíons 1
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a ln pairs, think about two or three productsyou use regularlyand discuss the followingquestions. o o
\r
What are the main functionsof the products? (Whatdo they do?) What are their different applications? (What are they used for?)
What do you know about Global Positioning System (GPS) devices? ln pairs, describe their main function, and give some examples of different applications of GPS devices.
2a
)1.1 Paula, a design engineer for a CPS manufacturer, is discussing product development with José, a senior manager new to the company. Listen to the conversation and complete the following notes.
o the primaryapplication of GPS more creative features
(l ) Trackingsystemsfor (2) Trackingsystemsfor (3) (4)
not technicalinnovations
(6)
associatedapplications
o
(s)
alarms buttons the technology
Complete the following extracts from the discussion with words that come from use. thot are reloted to 1 Then Aou've got associated applications, navigating... for monitoring deliverg vehicles ... 2 ... traclsing sAstems Aou can point of view, accuracg is no longer the main selling 3 . .. from the end-point. Most devices are accurate enough. The keg is to make them more
in use Unit 1 Technotogy
I 3a
Match the GPS applications (1-6) to the descriptions (a-fl. 1 2 3 4 5 6
a topographicalsurveyinggeotogical. b exploration \ \ c ciüt engineering avionicsequipment d maritimeapplications e f GPs in cars and trucks
naügation and safet1rat sea setting out positionsand levetsof new structures mappingsurhce features appticationsin miningand the oil industry highwaynavigationand vehictetracking air trafficcontrol,naügation and autopilotsystems
ln pairs, practise explaining the applications of GPS in Exercise 3a to a colleague who has limited knowledge of the devices using the following
phrases.
usedfor -ing
4a
usedto
usefulfor
another/ a similar use
Complete the following extracts from the conversation by underlining the correct words. 1 ... there's a setting on the CPS that allows/prevents it to detect the movement... 2 ... an alarm sounds to warn gou, and allows/prevents the boat from drifting unnoticed. 3 ... and enables/ensures that gou don't lose track of where gou were, which then enables/ensures uou to turn round and come back to the same point... Match the words in Exercise 4a to the synonyms.
: makessure
2-
I
: permits 3
= SIoPS
Complete the following extract from the user's manual of a GPS device using the verbs in Exercise 4a. Sometimes, more than one answer is possible.
you to locate your precise The core function of your GPS receiver is to (1) geographicalposition. To (2) the device to function, it receives at least three signals simultaneously from the GPS constellation - 30 dedicated satellites which (3) extremely precise receivers can function anywhere on earth. To (a) positioning and (5) errors from occurring due to external factors, this device is designed to receive four separate signals (see enhanced system accuracy on page 18).
In pairs, explain the main functions and applications of a product made by your company or a product you know about. Student A, you are an engineering manager; Student B, you are a new employee. Use the language from this section and the phrases in the box. Swap roles and practise again. I see.5o ...
0K. In otherwords...
So vou mean...
Unit 1 Technology in use
I
Exptaininghowtechnologyworks 6a
pairs, look at the picture and discuss the following questions.
ln o . . o
b
How do you think a space elevatorwould work? What could it be used for? What technicalchallengeswould it face? How seriouslydo you think the conceptof space elevatorsis being taken at present?
Read the following article and compare it to your answers in Exercise 6a.
lN his 1979 novel,Ihe Fountainsof Paradise,ArthurC Clarke wroteabout an elevatorconnecting the earth's surfaceto space. Threedecades later,this sciencefictionconcept is preparingto take otf in the realworld. NASA has launchedthe Space ElevatorChallenge,a competitionwitha generousprizefund,and severalteams and companiesare workingon seriousresearchprojects aimedat winningit. As its name suggests,a space elevatoris designedto Íaise things intospace' Sate||ites, componentsÍorspace ships, supp|iesÍorastronautstn space stations,and even astronautsthemselvesare examplesof payloads thatcou|d be tÍansportedjntoorbitwithoutthe need
C
The answeris by using an incrediblystrongand lightweight cable, strongenoughto support its own weightand a heavy|oad'The design oÍsuch a cab|eis This would be attached to a base stilllargelytheoretical. stationon earthat one end and a satellitein geostationary orbit(lixedabove a pointon the equator)at the other.Lift vehicleswould then ascend and descend the cable, powered by e|ectromagnetic Íorceand control|ed remotelv.
Match the verbs (l -9) from the text in Exercise 6b to the definitions (a-i). 1 2
connecting raise
a b
carried (objects, over a distance) hotdsomethingfirmty/ bearits weight
3
transpoÉed support
c d e f g
climb down providedwith energy/ moved by a force joining
h i
ctimbup tift / makesomething go up
4 5 6 7 8 9
7a
rockets. ÍorexpIosiveand environmentaIly unÍriend|y However,the altitudeof orbitalspace - a colossal35,790 km above the earth- is a measureof the challengefacing engineers.How could such a heightbe reached?
attached ascend descend powered controlled
driven / have movementdirected fixed
Space Elevgfors James, an engineer, is giving a talk on qble is signiícont. space elevators. o To (2) its own weighf, ond be securely (3) _________ o.! Complete his notes each end, cable would need phenomenal strenqth_to_weight ratio. using the correct _ . How could vehicles be (4) _ into form of the verbs cable? . Self-containe4 sltergv source problemotic, due to (l-7) in Exercise weight (heavy fuel ol 6c. (5) batferies required c u to tu \)/ _ _ vehic V enlcle.). ^)
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c Two possible ways round problem: _*:yt.l"r:,r,ry
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ut fechnique only ot research stage.
z , ' o l a rp o w e r . B u tw o u l d otuffio*ty. ""ty y:tt::!!:fblem, t-1\ ( // _
Unit 1 Technology in use
as cor could bu ,ortrollJ
payloads unmonned.
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_-
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8a
b
)t.Z tisten to part of James'talk and check your answers in Exercise 7a.
c
What kinds of word are missing from the notes? ln pairs, compare the audioscript on page 86 with the notes in Exercise 7a. Some space elevator designs propose an offshore base station. In pairs, discuss how such a system might work using words in Exercise 6c. What advantages might an offshore base have compared with a land base? )t.3 James goes on to discuss offshore base stations. Listen to the talk and answer the following questions. ] How wou|dan oÍfshorebase station be suooorted? 2 What would the functionof its anchors be? 3 How would payloadsreach the base station? 4 W h a t p r o b l e mw o u l da m o b i l eb a s e s t a t i o nh e l p t o p r e v e n t ? 5 What would the procedurebe if there was an alert?
9a
You are members of a space elevator research team designing a concept for offshore base stations. ln pairs, analyse the notes below, which were made during a briefing given by your manager. lmagine you are giving a presentation. Begin by reading out the abbreviated notes in full.
*\..\ \ \ L\
.......
\ L\r
L r r r r r r I I r r.r=l-L-t
Ú f 3 o 3l3 e 0 Ü 0 0 o t t o | |J
- AN'HoR|NGa?w?uL6l0N l56uÚ6 oFF6HoR'ÉAsE6TA.t1oN Anchoring ayatom ulindloadson Lablevrillbe huge.ulhatimplicaiions for anchoring slstom? Éase Willn?,od lo bgmovodcontinuall1, sometimes urgentl1. vrlhat tomp system couldbe ussdto holdbassin position? 9a* in shallowwatgrnearcoasi,or deepwalerfurtheroffshorg? óhoicewill haveimpacton dosignoÍanchors1stem. ?ropulsion ststem \^lillWeight oÍcab\e allowbaseto bs movedb1ownProPollors? Or more powerful 5.í5t9m for propulaion andcontro| noc.?o.g.ertern'powersource? !n pairs, discuss the questions raised in the notes and think of some suitable solutions for the anchoring system and the propulsion system. At this stage, these should be overall concepts, not detailed designs. Remember to make notes. ln small groups, take turns to give a short talk using your notes to explain how the systems work, in general terms. lmagine you are speaking to a small group of colleagues, including your manager. write two or three paragraphs to summarise your talk. These will be included in your manager's longer report on offshore base stations.
Unit 1 Technologyin use
technicaladvantages Emphasising
I 10
ln pairs, discuss the term technical advantage' Give some examples of technology you are familiar with.
77a
Read the first ParagraPh of some promotional literature from Otis, a leading elevator company. What is the Gen2" system?
OTISf,,ioJl
b tvtatctrthe words (l -6) from the text in Exercisel l a to the sYnonYms(a-0' 1 2 3 4 5 6
conventional eliminates \ superior \ \ energy-efficient enhanced reduces
a b c d e f
At theheartof theGen2ruelevatorsystem to byandunique be|t(deveIoped is a Í|at stronger it is Yet thick. 3mm is lt Otis). lust steelcables.lt lastsup thanconventional Andit hasenabled to threetimeslonger. The theelevator' re-invent Otisto completely eliminates belttotally flat,coated-steel effectof conventional themetal{o-metal with Coupled a smooth-surface systems. theresultis sheave, machine crowned andsuperior quietoperation exceptionally Ílat theÍ|exib|e Furthermore, ridecomfort. energya morecompact, beltenables whichcanbecontained machine, eÍficient This inthehoistwaY. enhancedtechnologY and reducesbuilding costs, operating system andfreesupvaluable space.
decreases better / the best improved standard,usual gets rid of has low energYconsumPtion
Completethe followingtext usingthe correct form of the words (1-6) in Exercise I I b' You will need to use some words more than once'
nar ,,0;;;;;;m ::p;ff:Y berts, pu,.r' inth.";ffi;,T#.
ilHlillililiuing
tliiltiügl;;:öm# H, Hli.űJ
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?jJ;:ll''' ;*;-ff ilT ffi ;;:í':fi matntenance personnel for
sYstem that1a)-
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10
system. Discuss In pairs, summarise the advantages of the flat belt automation' durability, wear, noise, space' cleanliness' efficiency' maintenance and cost. in use Unit 1 TechnologY
I 72a
Complete the following tips on emphasising technical advantages using the words in the box. conventionatetiminated enhanced reduced superior When describingtechnicaladvantages,it's usefulto emphasise... a(l)-performance,comparedwiththeo|dermode|ofthesame product. bnegativeissuesthathavebeen(2)-,orcomp|ete|y (3)_. c special features that differentiatethe technology from (4) sysrems. dperformance|eve|sthatmakethetechno|ogy(5)-tothe comDetition. )t.l Stefan, an engineer, is briefing some sales colleagues on the advantages of a new pump design. Listen to the briefing and match the tips (a-d) in Exercise I 2a to the extracts (l -4).
ExtractI -
Extract2 -
Extract3 -
Extract4
Complete the following sentences from the briefing by underllning the correct emphasising word. 1 2 3 4 5 6 7 8
We've come up with a completelg/significantlg unique profile. lt completelg/dramaticallg reduces vibration. Machines lilse these can never be entirelg/highlg free from vibration. The new design runs dramaticallg/extremelA smoothlA. Another advantage of the new profile is thot it's consideroblg/entirelg lighter. So compared with our previous range, it's highlg/totallg efficient. Trials so far suggest the design is completelg/exceptionallg durable. We expect it to be entirelg/significantlg more reliable than rival units.
Match the words in Exercise 12c to the synonyms. considenbly dnmatically entirely exceptionattyhighty totatty I
-l-
:completely
2
-l-
: significantly
3 -l-:
13
extremely
You are Otis engineers back in the l85Os, when elevators were new. ln pairs, prepare a short talk to brief your sales colleagues on the advantages of elevators for lifting people and goods. Emphasise the points below using the phrases and techniques from this section. Remember that people at this time are sceptical about the technology. Elevatorsare ... safe - a reliablebraking systemeliminatesthe danger of a car falling if a cable fails o simple - they'recontrolledfrom the car and are very easy to operate o
o o
convenient- they'reeasier on the legs than the conventional alternative (stairs) valuable- they enhancethe value of land by allowingtaller buildings on smaller areas Unit 1 Technologyin use
11
technical Simplifyíng andil[ustrating explanations
I t4
a )r.l Richard,a structural engineer,often takes clients on guided tours of their new buildingsduring construction.He is talking about explaining technicalconceptsto non-specialists.Listen and answerthe following questions. technicalconcepts? I WhatdoesRichardsay aboutexplaining 2 Whatdoeshe meanby dul/explanations? 3 What is beingpatronising? b ln pairs, think of some tips on how to solve the followingprobtems. I not being understood 2 beingpatronising 4 sounding dull
3 explainingdifficultconcepts
C )r.o Richard is giving some advice about the problemsin Exercise l4b. Listen and summarisehis ideas. Compare his tips with your suggestions. 15
d Richard has made notes for a guided tour of a site. The project is a skyscraperin the early stagesof construction.During the tour he explainsthe technical terms to the non-specialistgroup. ln pairs, discuss the following terms and try to interpret them using everydaylanguageto rephrasethem.
SUBSTRUCTURE Pi/e foundations Bored
(in generaD
in situ concrete
Pre-cast
driven
pi/es
concrete
pi/es
Pi/e driver 7/e auger Bentonite
)t.l Rictrarais givinga tour of a constructionsite. Listen and make notes of his explanationsof the followingtechnicalterms. Compareyour ideas with his. I the substructure the.e*rt.-of.th.e.5tvract$re.5 pre-castpiles 6 to drivein (a pile) be!p.w.9!,.q!^14.................... 7 a piledriver 2 a pile foundation 8 a pileauger 3 to bore (a pile) 9 bentonite 4 in situ concrete
t2
Unit 1 Technologyin use
I Listen again and compare Richard's explanations with the tips in Exercise l4c. Which techniques did he use? Were they successful? Complete the following table using the words in the box. basicatty(x2) ca[[ effectivety essentially imagine other picture refer sinrpk simply Function 1 Simpti[ring the language
Words/ Phrases 1n sinple terms/ put
2 3 4
whatwe if you-
Simptifoing the concept Focusing on technicalterms lltustratingwith images
/ -
/ / whatwe/ if you
/ in -words
f-
to as
ln pairs, practise explaining the technical terms in Exercise l5a using the simplified words and phrases in Exercise l5d.
t6
Read the textbook description of two types of pile foundation. Use the words and phrases in Exercise l5d and the following notes to rephrase it. From a structural perspective, pile foundations can be divided into two categories: end-bearing piles and friction piles.
lmargirnewartev
End-bearing piles are driven or bored through soft ground in order at\á the sea|beL to attain firm substrata below. The pile then transmits load vertically Like statrráitg o\ to firm subsoil or bedrock. The soft ground surrounding the sides of stilts i\ warfev the pile is structurally redundant.
luaargile ar leg a,|\), é\ Poo|
17
Friction piles counteract downward loads from the structure through frictional resistance between the sides of the pile and the surrounding ground, and do not therefore rely on firm substrata. In some cases, the diameter of the concrete at the pile's base is widened
Like ar h4il i\ woo)t
by compaction, allowing the increased area to give the friction pile a certain degree of end-bearing resistance.
You are showing a non-specialist visitor around your company and explaining technical concepts using simplified language. In pairs, practise explaining a product or type of technology that you are familiar with.
in use Unit 1 Technology
13
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UNIT 2
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a a o
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Describingspecific materiats Categorising materials Specifoingand describing properties Discussingquatityr issues
Describingspecificmateriats ln pairs, discuss the benefits and problems of recycling.Use the following examples and your own ideas. breaking up ships demol.ishing buitdings recycling electronicsscrapping cars
2a
Read the following web page and complete the missing headings using the words in the box. Aluminium Copper Gtass Plastic Rubber 5tecl Timber
1ííE c YcLABLE Li!ÁÍERl ALs t
Sfeel Scrap can be sortedeasilyusing magnetism.lf the metalis galvanised(coated withzinc)the zinc is Íu||y recyc|ab|e' |Íit is stain|essstee|,othermeta|smixedwiththe iron, such as chromiumand nickel,can also be recoveredand recycled. rE
2 Soding is critical,as thereare key differencesbetweenthe clearand coloured materialused in bottlesand Jars,and the high-gradematerialused in engineering applications,which containstraces of metals. y 3 Scarcitymakes recyc|ingespecia|lydesirab|e,and justiÍies the cost of removinginsulation Írome|ectricwires,which are a majorsource of scrap. Pure meta|can also be recoveredfrom alloysderivedfrom it, notablybrass (whichalso containsquantitiesof zinc, and oftenlead)and bronze(whichcontainstin). t4 The cost of meltingdown existingmetalis significantly cheaperthan the process of electrolysis, energy-intensive which is requiredto extractnew metalfrom ore.
rE
Hardwoodand softwoodcan be reused,However,the frequentneed to 5 removeironmongeryand saw or planeoff damagededges,can make the processcostly.
y
Tyresare the primarysourceoÍrecyc|ab|e 6 materia|. These can be reusedwho|e in certainapplications.They can also be groundintocrumbs which havevarieduses. y 7 An obstacleto recyclingis the need to son waste carefully. Whilesome types can be melteddown for reuse,manycannot,or resultin low-gradematerial. y a)
74
T
Unit 2 Materiatstechnology
I
Match the materials from the web page (l-8) in Exercise 2 to the definitions (a-h). 1 stainlesssteet.,''a 2 zinc I b \c 3 iron d 4 bronze e 5 lead f 6 hardwood g 7 ore h 8 softwood
a metalusedto makebrass,andin galvanisedcoatingson steel metalin steel the predominant a \rpe of steelnot needinga protectivecoating,as it doesn'trust a dense,poisonousmetal rocksfromwhichmetalscanbe extracted an a[[oymadefromcopperandtin timberfrompinetrees trees timberfromdeciduous
Compfete the following sentences using from, with or of . I Bronze containssignificantamounts o{ copper. 2 3 4 5 6 7 8
Calvanisedsteel is steel coated -zinc. iron. Steel is an alloy derivedalloys. Pure metals can usuallybe recoveredother metals. To producestainlesssteel, iron is mixed chromiumand nickel. Stainlesssteel containsquantities metals,such as lead. Glass tablewarecontainstraces ore, the costs can be high. When new metal is extracted
ln pairs, ask and answer questions about different materials using the following phrases.
3
a
lrina, an ecological adviser, is talking to a group of engineers on a training course about environmentally friendly design. ln pairs, discuss the ideas from her slide and give some examples. )z.t Listen to an extract from the talk and compare your ideas with what lrina says. What example does she use to illustrate her main point? )z.z lrina asks the engineers to do a simplified environmental audit. Their task is to compare steel and aluminium car bodywork from an ecological perspective. Listen to Sophia and Pete, two of the engineers, discussing the topic and make notes of their ideas. ln pairs, do an environmental audit for the following applications and materials. Use the words and phrases in the box.
Application wiresin vehicles I electrical 2 externalwallsin houses
Materials copperandaluminium bricksand softwood
I think so / I'd say so I'm (not) sure as far as I know ... thats an importantconsideration that needsto be researched coated derived mixed recovered recycled
-
Categorisingmaterials What do you know about braking systems? In pairs, discuss the following questions. I 2
5a
Cenerallyspeaking,what do brakes do and how do they work? What kinds of materialare used in brake pads and brake discs in different vehicles?
Read the article on braking systems. In the title of the article, what do the colours green and red refer to?
b
In pairs, answer the following questions. I 2 3 4
Why do most braking systemswaste energy? What are regenerativebraking systems,and how do they save energy? What characteristicsare requiredof materialsused for the brakes on racingcars? What is meant by heat soak, and why is it a problem in racingcars?
GREEN BrÜAKEs
- A RED HOT TOPIC IN MOTOR
RACING
As motor racing goes green, Formula I is aiming to lead automotive research in finding hi-tech efficiency gains. One of the keys to this ecological drive is regenerative braking (also known as kinetic energy recovery), which recovers generated during energy deceíeration.and stores it as a source of power for subsequent acceleration.
materials, and discs made of feÜous metal. The resulting friction generates heat, which is wasted. In performance cars, this phenomenon is taken to extremes, and due to the high temperatures generated, The potential for recovering brake discs are often made out energy also extends to the of ceramics. heat generated by engines The carbon discsand pads used and exhaust systems. This on Formula I cars generate area has also been discussed so much heat that they glow as a oossible area for future Regenerative brakes limit red hot. High temperatures exploitation in motor racing. the energy loss inherent in are, in fact, necessary for the Heat recovery might offer the traditional braking systems. In effective operation of carbon added benefit of reducing most vehicles. conventional brakes. But there3 still plenty heat soak ítherma|absorption pads of potential for recovering the by the chassisf as delicate brakes comprise previouslymade from asbestos- kinetic energy, rather than alloy parts and sensitive nonbased composites, but now mere|y dissípating it ín the metallic materials, such as polymers, are susceptible to consisting of compounds* form of heat. heat damage. of exotic. non-hazardous
C
Match the materiats from the text (l-7) 1 2 3 4 5 6 7
16
I
to the descriptions (a-g).
compounds1 a exotic \ U \ \ g ferrous
materialsthat are not metal iron and steel combinationsof materials
ceramics al.Loy non-metallic polymers
mixture of metals plastic materials mineralstransformedby heat rareor complex
d e f g
Unit 2 Materialstechnology
I
ln pairs, take turns to describe an object using the words from Exercise 5c and the phrases in the box. Ask your partner to guess what it is. comprise
consistof
madefrom
madeof
madeout of
6 a You are going to give a talk on compositestechnologyat a construction materialstrade fair. In part of the talk, you focus on reinforcedconcrete as a well-knownexampleof a compositematerial. Prepare your talk using words and phrasesfrom this section and the followingnotes.
hmpositematerials (ammonetample:reinforcedconcrete(verywidelyusedcomposite) Lement(derived fron lime)
(qravelor crushed ftgregate f:i:r:fgrrg"te(und)+clarseaggregate Water + chemical additives (e.9.plasticiser to improve w1rk^bility) kinforcement (steel barq fixed together withsteel tie wirQ
b
ln small groups, take turns to give your talk.
c
Margit, a sales engineer, is describing a high-voltage cable. Before you listen, label the cross-section with the parts (a-e).
a b c d e
insulation wateroroof membrane outerjacket armouredprotection conductor
2
)z3 tisten to the descriptionand check your answersin Exercise6c. Match the parts of the cable (a-e) in Exercise6c to the followingcategoriesof materials (l -5). You will need to use some parts more than once. I non-metallic at 4 non-ferrousmetal 2 metallic 5 polymer-based 3 ferrous metal Imagineyou are presentinga product or applianceyou knowwell to a potential client. Describethe categoriesof material used to make the different parts.
Unit 2 Materiatstechnology
t7
Specifyingand describingproperties
I 8a
In pairs, discuss what you know about the properties of Kevlar@and how it is used.
b
Read the following extract from DuPont'"'s technical guide to Kevlar@. Compare the information with your ideas from Exercise 8a.
\^/HATIS KEVLAR,@? KEVLAB@is an orgarricfiber DtrPontÍl'1 The in the arornaiicpolyanridefanri{y. properties lunique and distinctchemical Co|-1pos|Llon ot KEVLÁRe distingtrisn tllan nlade it Íromothercot-,rtllercia]' Íibers' KEVLAR@has a uniqueconrbination nroduius, toughness, abrasion of l'rrgh resrstance ar'crIlrernral stabilty.lt r,vas industrial developedfor der-nanciing applrcations. arldadvanced-technology rrany types of KEVLAR@are Currently. procluced to rrreeT a oroadrirngeof end usesthatrequirestrong,ltghtwerght. rraterials. cltirable CopyrightDuPontde Nemours
or its affitiates Company or trademarks of E.I.duPontde Nemours DuPont"andKevtar@ areregistered trademarks Find words in the text in Exercise 8b to match the following definitions. foraghness : the opposite of fragility 1 : resistanceto damage caused by friction 2 3-:reS|Stancetoproblemscausedbytemperaturechange 4 -: long-lasting : the opposite of heavy 5 -
9a
Match the automotive parts (l -5) to the descriptions (a-e). t drivebelts 2 brakepads 3 tyres 4 sealinggaskets armour 5 butlet-resistant
a b c d e
sheetsinsertedbetweenpartsto preventgasor fluid leakage pneumatic in contactwiththe roadsurface envelopes systems flexiblebandsusedin transmission gunshots protective barriers capableof resisting padspressed againstdiscsto inducedeceteration
Read the information from DuPont'uon the following page explaining some of the automotive applications of
[email protected] the text using the automotive parts in Exercise 9a.
18
Unit 2 Materiatstechnology
I
(1)haverncorporated Car and trr-rck Kevlar@intotheirconstruction becauseit offers
allolvthernto lastloi'rgand stop the rrelricle saÍe|y and qrtietly.
n ru lr t lavi r( u r roa . oe h r corlnu' J
Kev|ar@providesan eÍÍectlrle' 1ightweight (4)for r.'ehrcies solutiorr thatrequrre protectionagains{ballisticattack.allowingcars and lighttrucksto retainmost of theiroriginal handiingcharacteristics.
l O rU lHOl 'g)l)iOl
!8,
T h e h r g h| n o d U I U aS n c ja b Í a S | o lrle s | S t a l l c o ef Kevlar@ help (2) retaintheir or ginal c,h:np
an.l lprrcrnn n\/Ar lhe tTlrllrgpt Ot
revolrrt,crrts tlteuno througnoverlhe litespano{ a venrcte. The frictiona| Íorcesthat(3)are designed t o e n d u r et a k el e s so f a t o l lo r rt l \ o s en ' d d ew r t i r pulp.The enhancedthernralstability Kerrlar@ and inherentabrasionresistanceof KevlariS
C h e r n r c .srtl a i l i i i ta\1 o l l r e !! a ' s l a D , l ' ir)e i o make(5) reinÍorced with Keviar@pulp strongancjdurable.The gaivaniccorrosion resrstance of Kevlar'@ also contributesto irnprovediong ternrengrneperfonrance.
ln pairs, discuss why the properties of Kevlar@are especially important for each application described in the text. )Z.q Listen to a conversation about the properties of materials used in a specific type of tool and answer the following questions. 1 Where does the conversationtake place? 2 What tool is being discussed? 3 Which materialscan be used for its differentoarts? Complete the following extracts from the conversation using the properties in Exercise 8c. Listen again and check your answers. 1 2 5 4
The handle mustn't be heavy.ldeallg, Aou wont it to be Resistingfrictionis essential.The keg requirementisThe bur has to be built to last. Obviouslg, theg need to be verg Heat builds up in the bur. You need o good degree of -
Match the words and phrases ( | -5) from Exercise | 0b to the synonyms (a-e). 1 ideal.ty 2 obviously 3 the lastthingyouwant 4 the keyrequirement 5 a gooddegreeof
a
a iís clearthat b for the bestresults c the mostimportant fuctor d a lot ofl a hightevelof e the worstsituation
You work for a manufacturer of hand tools and have ;;;';;n* a investigate using alternative materials - in your products. ln pui.., ."uá tr'" notes and discuss the main properties required of the materials used to make the too|s.
.,-\ a! Joi're"s' hatmme's (tov rattls) chisels) ro)Ltau'rp hatwrmets(fov uaatsorrvy shart|. harmwrev the at\A heotA harr"rmer the Co\siáev a| Wooá Sarws(€ o v cta|tirrgwooá) Satws b) Harcksarws(fov craffirrg uaetatl) Coqsiáev |he satwb|oA,e aúO,|v\e sarwhatr,táleo" €varrre.
Harprme's
Think of a product you know well. ln pairs, discuss the materials used in it and what properties make the materials suitable. Discuss whether alternative materials could be used.
Unit 2 Materiatstechnology
79
qualityissues Discussing
I 72
In pairs, answerthe followingquestions. whathi-tech,high-performance I ln advertising, situationsare oftenusedto promotewatches? 2 Whatmessagesare theyintendedto sendaboutthe qualityof products? watches higher-quality 3 What qualityissuesdifferentiate ones? from lower-quality 4 What is the differencebetweendescribingsomethingas and waterproon water-resistant
13a
)ls touisa, a marketingexecutivefor a watch manufacturer,is discussingmaterial selectionwith Tom,one of her engineeringcolleagues.Listen to the discussionand completethe four quality issues that are mentionedin the meeting. I 2 3 4
b 14a
resistance -resistance -resistance -resistance
In pairs, discuss what is meant by each of the quality issuesin Exercise13a. )z.s tisten again and answerthe followingquestions. I What pointdoes Tommakeaboutthe reasonsfor selectingmaterials? steelto exemplifythe above 2 What does he say aboutsubmarine-grade point? of many 3 Whatproblemdoeshe describewithregardto the marketability materials? 4 What hard commercialfact does Louisagive? ln pairs, mark the followingstatementsTrue fI) or False (F)accordingto the viewsexpressedin the conversation.Read the audioscripton page 87 and check your answers. technically. materialsare notthat suitable, I Often,exotic-sounding 2 Peoplethinkthat a submarinesteelwatchmustbe tremendously water-resistant. good. 3 The corrosionresistanceof submarinesteelis exceptionally steellooksfairlygood. 4 Submarine-grade suitablefor watches. 5 Tomthinkssubmarinesteelis particularly 6 The firm has oftenused materialsthat are not adequatelydurable. 7 Often,the compositionsof good watchmaterialsare relativelycomplex. 8 Materialswith complicatednamesare prettygoodfor marketing.
20 I
E"
Unit 2 Materialstechnotogy
r
E-.C )z.O Listen to the followingphrasesfrom the conversationand undertinethe stressed syllable. Practise saying the phrases. I not patjeularlysuitable 4 tremendously marketable 2 exceptionally resistant 5 relativelycomplex 3 notat all suitable 6 notall thatgood d Completethe followingtable usingthe words in the box. cxrcÉia*y fairty insufficientty notadequatety not(alt)that notpartí.culartypÍetty ntativety tetendousty extremely
excepfiohrrlly
15
quite
not very
not enough
definitelynot
In pairs, discussthe key propertiesand differenttypes and grades of the followingmaterials.Give examplesof the propertiesthat make each material good or bad for watch-making,from a quality perspective. Materials steel glass atuminiumtitanium gotd ptastic copper rubber Properties
water-resistant abrasion-resistant corrosion-resistant shock-resistant touqh brittLe etastic durable heavy Lightweight thermaltystable
16
ln small groups,choose a well-knownconsumerproduct or applianceand discuss it from a quality perspective.How suitable are the materials used? How good is the product,comparedwith others sold by competitors?
Unit 2 Materialstechnology
27
Describing component shapes andfeatures
I t
What do you know about the electrical plugs and sockets used in different countries?ln pairs, describe some specificdesigns.
2a
)lt Jan, a project managerfor a firm that manufactureselectricalplugs and sockets, is briefing some of his engineeringcolleagues. Listen to the briefingand summarisethe aim of the project. fn pairs, discuss what is meant by profile of the pins and standard configuration.
tu
)U Erin, an engineerwith the same company,is describingdifferent electricalplug and socket formats during the briefing.Listen and matchthe descriptions(l -6) to the pictures (a-fl.
e_
22
Unit 3 Componentsand assembties
I d
Complete the following phrases from the descriptions using adjectives based on the words in brackets. 1 ... there are c\vcviav pins for live and neutral. (circle) 2 .. . the earth slot's got a flat base with one side over to form a semi-circle.(round) 3 This one has blades for live, neutral and earth... (rectangle) 4 ... it has a slot to receive the earth pin. (cylinderl 5 ... the pins are arranged in configuration. (line) (triangle) 6 ... theg're laid out in -configuration
g )t.l Listen and underline the stressed syllable in each of the following words. redangle cylinder 3
rectangular cylindrical
triangle line
triangular linear
a
)S.l Listen to a longer description from the meeting. Which picture (a-0 in Exercise 2c does Erin describe?
b
Complete the following extracts from the description using the correct form of the words in the box. flushwith groove ffie
pin recess ridge set back
V,ole 1 ... there's a circular slot at the top. It'sobviouslg a btind , i7 doesn't go right through. 2 . .. there ore two plastic , one on either side of the plug casing, and theg slot into corresponding at each side of the socket.lnaddition.thecentreofthesocketls-.Soratherthan being the front of the socket, on the same face, the circular area that receives the plug /s from the surrounding casing ... 3 These covers onlg open when pressure is applied to both bg the two - of the plug simultaneouslg.
4
C
!n pairs, describe the different plug and socket formats in the pictures in Exercise 2c.
a
)l.s Andy and Karin, two electrical engineers, are evaluating a plug and socket format in Exercise 2c. Listen to the conversation and make notes of the advantages and disadvantages of the following features. 1 Plug slots into a recessin the socket: Advantages Disadvantages 2 Covers protect live and neutral slots: Advantages Disadvantages
b
ln pairs, discuss the advantages and disadvantages of the plug and socket formats in Exercise 2c. Use the following phrases from the conversation. an advantage/disadvantage of this formatis ... anotheradvantage/disadvantage is ... withthis systemis ... this (shapeformatfeature) the problem stops... from... -ing this (shape/format/feature) attows it to ,/ hel.ps it to / makesit easyto / makesit difficuttto ...
Unit 3 Components and assemblies
23
n
Explaining manufacturing andassessing techniques 5
ln pairs, think of some examples of machining operations that are often used in manufacturing involving metalworking.
6a
)l.S Suan, a sales engineer with a metal fabrication company, is showing Mr Barrett, a new customer, around their plant. Listen to the conversation and mark the statements Ti'ue (T) or False (F). I The company specialisesin sheet metal working. 2 The company does a lot of metal casting. 3 Metal bashing is a precisetechnicalterm for hammering. 4 Drills and milling machinesare alwaysnoisy. 5 Crinding is a processthat uses abrasives. 6 The press is used for shearingmetal. Complete the following training material for graduate engineers using the words in the box. Dritting Flame-cuttingMitting Sawing Shearing
l'|fiilÜilGT||R |l|GItGl|l|l0ut HnlÜ[I|0l|: cl|ITll|s0ptllll 0l|s Key Íactorsin determiningthe most appropriatecuttingtechniqueare:materia| characteristics(notablyhardness,and thermaland electricalproperties), componentthickness,componentshape and complexity,requirededge quality,and \ productionvolume.Select cuttingoptionsbelow for a detailedanalysisof techniques.
Gunil8oPiloilS
(1)-:abrasivecutting,removingakeíoÍmateria|.|nc|udescuttingwithtoothedb|ades and abrasivewheels. @ (2)-:useofpressureonsmooth-edgedb|adesforguillotiningandpunching@ (3)-:remova|ofmateria|acrosstheÍu||diameteroÍaho|e,orusinghole-sawsfor kens. j!!il!* cuttingcircumÍerentiar (4)-:remova|ofsurfacelayerswithmu|tip|ecuttingwhee|passes@ (5)-:usingoxyfue|(oxygen+combustib|egas'oftenacety|ene).@
C Complete the following definitions using the words in the box. abrasivewheel guitLotine hole-saw kerf
punch toothedblade
pq\ch I A makes holes by applyingpressureto shear the material. 2A-makesstraightcutsbyapp|yingpressuretoshearthe material. is the width of the saw cut. 3 A4 Ahas sharp edges for cuttingor milling. has a hard, rough surfacefor cuttingor grinding. 5 A6A-cutsacircularoiecetoremoVeanintactcoreofmateria|. 24
I
Unit 3 Components and assemblies
I 7
a
Read the following extract of promotional literature from a leading producer of ultra-high-pressure(UHP) waterjet cutting machines. ln pairs, explain the phrases in bold.
= Ffow
sucha popularcuttingoption? \ A /hat makeswaterjets jets V V Water requirefew secondaryoperations, producenet-shapedparts with no heat-affectedzone,heatdistortion, or mechanicalstressescausedby othercuttingmethods, can cut with a narrow kerí and can providebetterusageof raw materia|sinceparts can be tightly nested.As a resultof the FlowMasterruPC controlsystem and intuitiveoperation,waterjetsareextremelyeasyto use.Typically, partsin operatorscan be trainedin hoursand areproducinghigh-quality hours.Additionally, waterjets virtually cancut any material,leaving a satinsmoothedge. )l.l fvan is talking to Mr Barrett about UHP waterjet cutting. Listen to the conversation and match the phrases in the box to the extracts (1-4). heat-affected zone
mechanical stresses narrowkerf
Extract I Extract 2
parts net-shaped
Extract3 Extract4
Complete the following extracts from the conversation by underlining the correct phrases. 1 So theg are especiallg good when / not so good when gou have intricate shapes. 2 Saw blades are obviouslg pertect when / useless when you're cutting curved shdpes. 3 ... sawing is the ideal solution / not the best solution if gou want to avoid altering the material. 4 ... it's ideal for / totallg unsuitable for metals.
8
In pairs, assess the different cutting techniques in terms of o shape/size of cut o material types/characteristics . phrases Use the in the box.
cut width/quality.
good for + -ing the ideal./perfect ideaL/perfect/especiaU.y solutionfor not particutarlysuitable/ not so good if you need ... not the best sotutionif you don't want ... totalty unsuitabte/ useless
Cuttingtechniques dril.l.ing with a bit dritLingwith a hole-saw flame-cutting grinding gui[[otining mil.Ling punching sawing waterjetcutting
Shape/sizeof cut angular bLindhol.es curved large sma[[ straight thick thin throuqh hotes Material types/characteristics ceramics metals plastics timber hard tough brittte Cut width/quality heat-affected zone narrowkerfs no kerf roughedges smoothedges widekerfs
Unit 3 Components and assemblies
25
Explainingjointing and fixingtechniques
I 9
In pairs, think of some examples of ways of joining materials together.
10a
)g.A pearo, a purchasing manager with a kitchen appliance manufacturer, is talking to Alicia, a sales manager from one of their main suppliers. Listen to the conversation and answer the following questions. 1 What objectivedoes Pedro describe regardinghis company'srelationship with suppliers? 2 What is Alicia concernedabout? 3 How does he respond to her concerns? Complete the following table using the words in the box. adhesive ü'ott
ctip
Mechanicalfixings bolf
C
rivet
screw weld
Non-mechanicalfixings
Label the photos (l-5) with the words in Exercise lOb.
l
welá
3_
Match the types of connection in the box to the following groups. botting bonding connccting fixing gtuing joining riveting welding 1 corr\ectiqg 2 -
only. 26
: describes any kind of connection. : describesmechanicalconnectionsonlv. : describesnon-mechanicalconnections
Unit3 Components andassemblies
T l1
d
Complete the following questions using the words in the box. eachother on onto to together I 2 3 4
How can we fix these two componentsHow can we fix these two componentsto H o w c a n w e f i x t h i s c o m p o n e n t- ? How can we fix this component I-
? ? this component?
b Complete the following training web page using the words in Exercise | | a.
a
il[ilUrA8IUB ll|Bllcl|l|l|lÜtEURIÜII! 0l|:J0ll|Isll|l| rilIilBs The most suitable method ot joÍning components depends on many tactots, whích extend beyond the obvious íssue oÍ requírcd strength. .
Wil|the .jointneed to be disconnectedin the Íuture?|Ía part is bo|ted(1), it can obvious|y be removedat a |aterdate. |Ítwo componentsare bonded to (2)with strongadhesive,or welded (3)then subsequentremovalwill clearlybe more difficult.@
.
What externalfactors might affectthe joint? Water or heat can weaken adhesivejoints.And no matterhow tightlynuts are screwed (4)bolts, vibrationcan cause them to work loose ^.,^- +i-^ vvvr Lil rv.
.
4tllF tllllliblr
each How quality-sensitive is the jointingtechnique?Componentsare rarelyjoined(5)other in idealconditions.lnadequatelytightenedfixings,improperlypreparedsurfaces,or flawed welds are inevitable.How could such imperfectionsaffectthe jointnegatively?@ -
<'t
C In pairs, answer the following questions using the information on the web page in Exercise 1I b. I What are the main advantageand disadvantageof mechanicalfixings? 2 W h a t i s t h e m a i nd i s a d v a n t a go e f n o n - m e c h a n i c jaol i n t i n g ? 3 What issues can negativelyaffectmechanicalfixings and non-mechanical joints? 72
a
ln pairs, discuss the followingjointing techniques used in aircraft and say how the parts are fixed together. 1 2 3 4
Early aircraft:timber frame / adhesiveor screws Modern jet aircraft:alloy body panels / rivets Aircraft cabins:seats/floor/bolts Aircraftcockpit:windshield/fuselage/adhesive
b Your company has launched a competition for its engineers to build a homemade model glider that is as cheap as possible to assemble. ln pairs, discuss what types of materials and joints you could use.
Unit 3 Components and assembties
27
nDescribingpositionsofassemb1edcomponents 13a
ln pairs, read the title of the article and suggest ways of making a garden chair fly. Discuss any potential problems.
b
Read the article and match the questions (a-d) to the paragraphs (l -4). a b c d
How did the actual flight differfrom the one that was planned? What incidentsoccurredjust beforeand just after the landing? What is said about the modern equivalentof this type of activity? What componentswere used to assemblethe flying machine?
CRAZYBUTTRUE:LARRYWALTERSANDTHEFLYINGGARDENCHAIR I On July 2, L982, a Californian truck driver named I-arry \ü?'alterssat outside his house on a garden chair.To say that he was out to get some air for is an understatement, projecting above him a cluster of ropes was tiedto 42 heliumfi lled weather balloons. Anchor ropes, situated underneath úe chair, were fastened around the bumper of his car, which was positioned just below the makeshift flying machine. 2 MrWalters intended to climb gently to an altitude of a few hundred feet, before drifting slowly out of town and across country. He then planned to use an airgun to shoot some balloons and descend
gradually to earü. But as the helium gas contained within the balloons warmed up in the summer sun, it progressively generated more lift. \ü7hen the anchor ropes were released, the self-assembly airship shot up like a rocket. Too shocked to reach for üe pistol inserted in his pocket, the first-time pilot held on for life. In iust a few minutes, l-arry rWalters was 16'000 feet above üe ground, floating over the city of l-ong Beach. A short time later, there were furüer complications; he suddenly found himselfinside controlled airspace, adjacent to Long Beach Airport. The occupants of passing Delta Airlines and T$íA aircraft looked on at the
curious spectacle outside, as wide-eyed as the garden chair pilot hovering beside them. Evenrually, after managing to shoot some balloons, Mr Walters descended safely to earth despite an anchor rope, which was still suspended beneaú üe chair, getting tangled with a power line located alongside the landing site (in someone's garden). He was immediately arrested by waiting police of6cers, and was later fined for breaking Federal aviation laws. Today, cluster ballooning, while still a fairly marginal sport, is steadily starting to gain in popularity.
C Answerthe questionsin ExerciseI 3b. 74
a Label the diagramsusingthe prepositionsin the box. abor/e adjacent to alongside around below beneath beside inside outside over underneath within
a
!
u
atbove
'!.
,ffi
a
28
U n i t 3 C o m p o n e n tasn da s s e m b l Í e s
"8.
I complete the following sentences about the flying garden chair using the prepositions in the box. Check your answers against the text in Exercise t 3b. in
above around beneath within
the chair was a clusterof ropes' tied to 42 1 Projecting helium-filledweather balloons. the bumper of the car. 2 Anchor ropes were fastened his pocket. 3 Larry Walters had an airgun inserted t h e b a l l o o n sw a r m e du p i n t h e s u n ' 4 T h e h e l i u mc o n t a i n e d the chair. 5 After takeoff,the anchor ropes remainedsuspendedcomplete the following descriptions of how the garden chair airship was assembled by underlining the correct words. I A quantityof helium gas was contained/suspendedinside each balloon. 2 A tube was inserted/projectedinside the openingsof the balloons,to inflate them. 3 The balloonswere situated/suspendedover the chair,in a large cluster. 4 The chair was containedisuspended under the balloons by ropes. 5 Arm rests,contained/locatedbeside the pilot, at each side, helped to hold him in place. The landinggear,inserting/projectingbelow the seat, consisted,simply,of the chair legs. 7 The pilot was positioned/projectedunderneaththe balloons,so his weight was low down. d
Wtrictr two other words have the same meaning as positioned? contained
t5
fastened
inserted
Located
projected
situated
suspended
a In pairs,look at the photo and describehowyou think the cluster balloonis assembledfrom the followingcomponents. bags balloons helium nytonropes nylonstraps pLasticcabte sand/water batlast ties tape
paragtiding harness
b )il Eva and Lenny, two engineers working for an extreme sports equipment manufacturer,are discussing cluster ballooning. Listen to the conversation and summarise what they say about the following issues. the advantageof tying I a s s e m b l yt i m e e a c h i n d i v i d u abl a l l o o n 2 how olastic cable ties are used the problem of using a net 3 a tree structure to containthe balloons 4 how water bags are used In pairs, discuss ways of overcoming the problems mentioned in the conversation. How could cluster ballooning be made more accessible to a mass market? What other equipment/assembliescould be used?
and assembties Unit 3 Components
UNIT 4
E
. Workingwith dnwings o Discussing dimensions and precision o Describing designphasesand procedures o Resolvingdesignproblems
rI
.n fL j$ r-.9Íl
I
lltt
l - r; r -
{;
ilil
.-f
-:StT.: *
l l
e
a
p
NI
I
r+ lJ " I
.6 tf,d*
.; ..1
r*'ii$*i* ffiitrLn: u-
fa
?
I
I
Workingwith drawings ln pairs, discuss the different types of design information needed on a complex engineering project, such as the construction of a large cruise ship. How many different drawings do you think might be produced for such a project? How would they be organised and categorised?
2a
)l.t loe, a technician at a shipyard, is talking to Linda, one of his engineering colleagues in the design office. He is asking about some information which he can't find on any of the drawings. Listen to the conversation and answer the following questions. I What area of the ship are they discussing? 2 What does the technicianneed to know? Complete the following definitions using the types of drawing in the box. cross-section elevation explodedüew specification p\art\ 1 X 2 An 3 An together. 4 A5 A6 Adrawing. 1 A-
note
phn
schematic
gives a view of the whole deck, trom above. gives a vlew of all the panels,from the front. gives a deconstructedview of how the panels are fixed gives a cutawayview of the joint betweentwo panels. gives a simplifiedrepresentationof a networkof air ducts. gives a brief descriptlonor a referenceto another related gives detailedwrittentechnicaldescriptionsof the panels.
Which two types of drawing in Exercise 2b are examples of general arrangement drawings, and which two are examples of detail drawings?
30
design Unit 4 Engineering
.-j;t'
t"
-
b--
Read the followingtechnicalquestionsthat came up during the shipbuildingproject and decide whichtype of drawingis requiredto answer each question. lHowmanypane|saretherealtogetheronthiswa|l?2 What profileare thesehollowbeams:rectangularor circular? 3 Whatare the positionsof all the floodlightsaroundthe deck perimeter? 4Howmanybranchescomeoffthemainsprink|ersupp|ypipe?of the fan unitfit together? 5 Howdo all the internalcomponents
3a
What is meant by scale on a drawing? ln pairs, o
b
)u nfter receivingthe drawings for the panets,Joe is now discussing some details with Pavel, a colleague. Listen to the conversation and answer the followingquestions. I What pieceof informationis not shownon the drawing? 2 What golden rale is mentioned? Complete the following extracts from the conversation and explain what is meant by each one. I /s fhis drawing scale? 2 lt's one five. 3 ... gou shouldn'tscale drawings... 4 ... it's actual size,on a --scale drawing...
4
You are engineers on a proiect to design the metal handrailthat will run around the perimeter of the top, outdoor deck of a large cruise ship. !n pairs, discuss what drawings you will need to produce for manufacturingand installation with regard to the followingissues: o the typesof viewthat will be requiredand whateach one will show o the approximatescaleof differentdrawingsand views o whatwritteninformationyou will needto providein the specification.
5
You are going to provide design information to enable a productionteam to manufacturea product or applianceyou knowwell. Make a list of some of the drawingsthat will be needed,notingwhat each one willshow.
Unit 4 Engineeringdesign
Discussing dimensionsand precision 6
d
ln pairs, discuss what is meant by precision and accuracg. Read the technical advice web page and answer the following questions. 1 How is a superflatfloor differentfrom an ordinary concretefloor? 2 What accuracycan be achievedwith ordinary slabs, and with superflatslabs? 3 What problem is describedin high bay warehouses?
Floors:FAO SuperÍlat
What is a superflatfloor? process. thesurface is aninherent|y imprecise Foranordinary Compacting andfinishing oÍWetconcrete engineers canonlyrealistically expect thesurface to befinished concrete slabto belaidwithintolerance, to plusorminus superflat concrete floors arefinished to meetextremely closetolerances, 5mm.Bycontrast, '1mm beingaccurate towithin across theirupper surface. Where are superffatfloors used? specified inwarehouses whereAutomated FloorsurÍaces withextreme|y tighttoIerances areÍrequent|y problematic Vehicles floors areespecially inhighbaywarehouses, whichuse Guided operate Uneven fork|ifts reachoÍ30metres ormore' At sucha height, s|ight variations inÍ|oor automated witha verticaI |eveI intheformoÍverticaI ti|t,causing inaccurate manoeuvring at high|evel' |Íthese areamp|ified variations tolerance theycanleadtocollisions withracking elements, orcauseitemsto be areoutside pa||ets. Írom dropped
ln pairs, discuss what is meant by tolerance in the context of dimensions and precision.
d
Complete the following expressions from the web page which are used to describe tolerances. I tolerance(insidethe limits of a given tolerance) 2 -or-Smm(+/-5mm) 3 tolerance(closetolerance) 4-to|erance(notinsidethe|imitsofto|erance)
e
Complete the following sentences using the expressions in Exercise 6d. The frame'stoo big for the opening.The opening'sthe right size,so the frame mustbe 2 The total t o l e r a n c ei s I m m . T h e o e r m i s s i b l ev a r i a t i o ne i t h e rs i d e o f t h e i d e a l is The engineerspecified + / - 5mm for the slab finish,and we got it to + I - 2mm. So it's well 4 You can't finish concreteto + / - 0. I mm. There'sno wav vou can work to such I
ln some situations, engineers describe tolerances using p/us or minus, for example +/ - I mm, and in other situations as within, for example within lmm.ln pairs, discuss the difference in meaning between these two descriptions, giving examples of situations where each description might be used. 32
Unit 4 Engineering design
I
7a
)q.i f\4ei,a structural engineer, is talking to Lewis, a project manager, about the floor specification for a manufacturing plant that is currently at design stage. Listen to the conversation and answer the following questions. I 2 5 4 5
What has the client requestedwith regard to the floor slab? What are free movementfloors and defined movementfloors? What issue does the engineerdiscuss regardingquality? W h a t o p t i o n i s d i s c u s s e di n v o l v i n gg r i n d i n g ? What can be done to the reinforcementto permit grinding?
Complete the following table using the words in the text in Exercise 6b and audioscript 4.3 on page 89. 1 2 3 4 5
Nameof dimension Whafsthe-? wiá|h Whaís11]g ? What'sthe-? What's11gthickrress? What'sthe-?
Largedimension Is it -? Is it -?
Smat[dimension
Is 11high Is it -?
Is it [ow?
7
Is i1 a\eep 7
Is it short? Is it nanow? Is it thin? Is it shallow?
Mei has done a revised drawing for the floor slab. Read the extract from her email about the new design and complete the message using the correct form of the words in Exercise 7b. To: Lewis Rosas Subiect: Bevised floor slab drawing
P|easefind attacheda reviseddrawingÍorthe Í|oors|ab,now reconfiguredÍordefinedmovement. wiáe (as specifiedby the c|ient) |n orderto accommodateguidedvehicIes1 08Omm(1) WepropoSeastandard(2)-of1280mmforeachsuperf|at|ane.At14.5m,the (3)-ofthe|ongest|aneonthenetworkiswithinthemaximumslabrunthatcanbecast in a singleconcretepour,thus avoidingconstructionjointson straightruns.On curved sections,a recommendations. standard8.5m turningradiusis used,as per the guidedvehiclemanufacturer's |norderto a||owfor the eventua|ity of futuregrinding,we have |ocatedthe top |ayeroÍreinÍorcement has not, however,been 1Ommdeeper below the slab surface.This additional(4)added to the overallslab (5) , which remains275mm.The reinforcingbars also remain - many of which need in I2mm diameter.As a result,the levelsof wall-mountedprocess installations precise (6) above finishedfloor level are unaffected. to be fixedat a -
8
Which two words in the email relate to circles? What aspects of a circle do they describe? W The manufacturing plant in Exercise 7 will be built from a steel frame. The vertical elements of the frame will be Universal Columns (UCs). Look at the section of a UC. ln pairs, describe the different dimensions that define a UC profile by explaining what the letters on the section refer to.
flanges
TI Unit 4 Engineering design
33
Describingdesignphasesand procedures
9
!n pairs, discuss what is meant by a design process.lnengineering,what are the stages in the developmentof designs?
10
a The followingextracts from emails relate to a projectto build an indoor ski complexin Australia, using artificial snow.The messageswere circulatedby an engineerto membersof the design team, and to a specialistcontractor. Read the emailsand, in pairs,answerthe followingquestions.Note that the emails are not in the correct order. I Whatare all the emailsabout? 2 Whatdifferenttypesof documents are mentioned? We now have a fullset of workingdrawingsfor the main ski lift(attached). These incorporate some amendmentsrequestedby the client, which have now been approved.Hard to the re|evant copies have been Íoruvarded contractors'premises,for fabrication. .
It I i ;
.. P|easefind attacheda fu||set oÍpre|iminary II drawings,as submittedto the clientfor approva|/ comments.These are Íorinformation , only at this stage.
o Attachedare a few roughsketchessetting out the overalllayoutof the ski complex.At this point,these are initialideas based on the client'ssuggestionsand the approximate dimensionsspecifiedin the design brief.I look forwardto any feedback by the end oÍthis
week.
b
|| l|
I attacha summaryof our meetingwith the clientlast Tuesday.lt outlinesideas expressed OVthe client'smarketingteam, and describes what an experienceat the ski complex should be like,from a visitor'spointoÍview.We'||be Soingthroughthese notes at the prolectkickoÍÍmeetingnextThursday,to c|arifythe design brieÍ,so p|easeÍormulate any queriesbeÍore then.
" Please note that dwg 18A is currentlybeing revised,to resolveproblemsencountered duringassemblyof the ski lift.BevisionB will be circulatednext week. Untilthe amended drawingis issued,pleasetreatdwg 18A as superseded.lf you requirespecificdetails urgently,please contact me, and I will arrange Íora suitab|esketch to be issued'
II
Put the emails in the correct sequence. l_2_3_4_5
C Complete the following definitions using the types of drawing in the box. designbrief
pretiminary drawing sketch workingdrawing
lA-isaroughdrawingofinitia|ideas,a|sousedwhenproduction problems requireengineersto amend design details and issue them to the workforceimmediately. 2A-isawrittenSummaryintendedtospecifydesignobjectives. 3A-isanapproveddrawingusedformanufacturingorinsta||ation There is often a need to revisethese drawingsto resolveproductionproblems. In this case,amended versionsare issued to supercedethe previousones. 4A-isadetai|eddrawingthatco||eaguesandconsu|tantsare invitedto approve if they accept them, or commenton if they wish to request any changes. 34
design Unit 4 Engineering
I
Ll
d
Find synonyms for the following words in the definitions in Exercise I Oc. 5 give feedback | 1 accept I aQ?vo\le 6 rePlace/uPdatel2 a m e n dl 7 statel3 approximatel8 solvel4 circulatel-
e
In pairs, suggest what needs to be done next in each of the following situations. 1 They'vefound a problem with drawing63 on site.The detail we'vespecified doesn'twork. 2 I'vedone a preliminarydesign for the duct layout,but the client hasn't seen it yet. 3 I'vegot a feelingthe drawingthey have on site isn't the latest one. 4 We'vejust reviseddrawing 14. The changesare going to affectthree different contractors. 5 This is the client'swritten design brief. How shall we kick off the design work?
a
Leo is the ski complex proiect manager. With design work about to begin, he is meeting senior engineers from the design teams to discuss design coordination. ln pairs, exp|ain the items on the meeting agenda and suggest what kinds of issue might be discussed.
b )tl Listen to three extracts from the meeting and match each extract (l-3) to an agenda item (a-c). l_ c
2_
Australian Ski complex - Design Coordination Meeting Agendj Tuesday 8th May ConÍerenceroom 9.30am - í 1.00am To: RN, LG, SB, CW, Sft ltem a
Design interface(mechanical. etectrical)
b
Design and inÍormationÍ|owprocedure (structural'mechanical, electrical)
c
Inter-teamcommunicationÍorma|and informa|
3_
}l'l Listen again and make notes about the problem. discussed in the meeting. ln pairs, discuss some possible solutions to the problems.
d }s.s Listen to Leo summarising the solutions that have been agreed in the meeting. What has been decided regarding the following Points?
The decisionthat the senior engineerin each team must make, regarding drawings 2 The circulationprocedurethat will be used for each drawing 3 The role of the M&E coordinatorin relationto the senior engineersand the projectmanager 4 The arrangementthat will make informalcommunicationeasier I
e
ln pairs, discuss how the design procedures discussed in the meeting will work in the following situations. I lssuingthe first draft of a specialisedhydraulichose drawingfor the ski lift 2 Designingan electricalsupply systemfor some water-coolingequipment 3 Revisingthe connectiondetails betweensome ski-liftmachineryand its concretefoundation
design Unit 4 Engineering
35
Resotvingdesignproblems
f 72
In pairs, discuss problems that can arise when different drawings that make up a design are not properly coordinated.
13
d The following records are from the indoor ski complex project. They show correspondence between the design team and construction team. Read through the texts quickly and answer the following questions. I What is the general subjectof the correspondence? 2 What is meant by querg and instruction? 5 Some queries refer to earlier conversations.Suggestwhy these have been followedup in writing. 4 What is meant by dwg and dims?
coNTRAcToR,s QUERYNo.8ó7
ENGINEER'SINSTRUCTION
Followingour telephoneconversotiontodoy,we note thotthere is o discreponcybetweendwgs ZóE ond78E, which indicoteconÍ|icting dimensionsfor thewidthof the roofopening.Pleoseclorifywhich dimensionis correct.
We confirmthe correctdimensionis on dwg 7óE. Pleosedisregordthe dims on dwg Z8E.
coNTRACToR,sQUERYNo. 8ó8
ENGINEER'SINSTRUCTION
As discussedthismorningon site,we confirmthere Pleosework to ottochedsketchS33. is o closh betweenthe proposedcoble hoy (dwg Revisionof dwg E5ó to fo||ow. E5ó} ond oir
coNTRAcToR'sQUERYNo.8ó9
ENGINEER'SINSTRUCTION
A noteon dwg 1 1A specifiesblock boltsot the Pleoseprovide furtherdetoi|soÍthe HSFG bo|tsyou bose of the ski liftcoble support.Thiscontrodicts the ore proposing. specificotion, which stotesthotoll iointsto comprise High StrengthFrictionGrip bolts.We proposeusing HSFG fixingsot thislocotion.
CONTRACTOR'S QUERYNo. 870
ENGINEER'SINSTRUCTION
Furtherto Query 8ó9, the proposedHSFG bo|tsore Approved. os per thosespecifiedfor oll otherboltediointson the ski liftsupports.Our intentionis to use o single boltspec to focilitoteossembly. Read the correspondence in detail. Write the query numbers in Exercise 1 3a next to the descriptions (l -5). You will need to refer to some queries more than once.
36
l 2 3
An insta||ation that won't fit, aS componentsare in each other's way 8é,8 A responsefrom the engineerasking for more information Oueries that suggesta solution,which will requirethe engineer'sapproval
4
Requeststo the engineerto instructthe contractoror make somethingclear.
5
Separate documentsreferringto details that don't correspondwith each other
Unit 4 Engineering design
T { C Complete the following pairs of sentences using the verbs in the box. advise ctarifo ctash propose request . I The componentsare in each other'sway. : The componentsmore information. 2 Please ask for more information.: Please a solution? 3 Can I suggesta solutionto the problem? : Can | 4 Please instructthe supplierto send the parts to this address. : Please the supplier. any 5 Any conflictingdetails must be queried. : You must conflictingdetails. 4
a
In pairs, look at the following plan and sections from a drawing on the ski complex project, showing steelwork details on part of a ski lift. Examine how the rectangular plate is bolted to the T profile below it. Can you find the discrepancy between the details, and the clash preventing the connection from being assembled?
ooo oo ooo
Section A-A
Section B-B
Chen, a technician, is explaining the problem in Exercise 14ato Ron, an engineer. Complete the conversation using the words in the box. alternative as per ctarifo clash confirm contradicts djtc'€e'afiey propose Chen: There3 o (1) áiscvePartrc/ between these detai3 that gou might be oble to (2) straight awag. On the plan of this plate, it shows eight bolts. But on section A, here, there are no bolts shown in the middle,Sotherewouldonlybesix,whichobviousla(3)-the plan. But as Aou can see, this plate's going to be bolted to a T profile. So we couldn't put a row of bolts down the middle, because theA'd (4) with the flange running along the middle of the T. So I'd just going for two rows of bolts. The (6) (5) would be to redesign the T section, which would obviouslg be a bigger job. Ron:
Yes. Let's go for two rows of bolts, (7) -
Chen: OK fine. Will gou send an email to (8) -
the sections. that?
)o.g tisten to the conversation and check your answers to Exercise l4b. How does the explanation compare with your description of the problem? Write an email from Ron to Chen, confirming the revision agreed in the discussion above.
Unit 4 Engineering design
37
rt! t I a
Describing typesof technicalproblem
I 1
In pairs, discuss the technical challenges of endurance car races like the Le Mans 24 Hours sports car race.
2a
)S.t Sanino, an engineer with a sports car racing team, is giving a talk to some of his team's sponsors at a test session. Listen to the talk and answer the following questions. 1 What saying emphasisesthe importanceof reliability? 2 What expressionrefersto things that can cause failures? 3 What expressiondescribesdamage caused by normal use? )s.t ln the talk, Sabino names five engineering enemies. Complete the following list. Listen again and check your answers. : high temperatures I h: loads from expandinggases or liquids 2 p3v-:continuoushigh-frequencymovementorshaking : sudden impacts 4 s: damage to surfaces caused by friction 5 aln pairs, suggest which engineering enemies in Exercise 2b can be the most problematic for each of the following car parts. I chassis 2 engine 3 gearbox and clutch
3a
7 ö J
wrngs coolingsystem nutsand bolts
)s.z tisten to Sabino talking about some technical problems the team have had at the test and mark the following statements True (T) or False (F). I 2 3 4 5 6
38
4 suspension 5 brakes 6 tyres
Some liquid was lost from a pipe. A car lost all its coolant with the engine still running. A car's engine stopped on the circuit. Some tyres were damaged. A wheel nut fell off a car on the circuit. A car's suspensionwas broken.
Unit 5 Breakingpoint
:
I
b Complete the following extracts from the talk using the worCs in the box. bend blochng cnck jam snap the airflow to the radiators. 1 ... gou don't wdnt ongthing 2 ... theg had a wheel nut , it wouldn't turn. the suspension or 3 ... he didn't hit the barriers and it completelg. 4 ... it didn't the tub - the chassis. C Complete more extracts from the talk using the correct form of a verb in box 1 and a word in box 2. 7 blow ctog cut leak run wear rvo'r*
2 toose up out
loose on a radiator pipe, which resulted in coolant 1 ... a y1u1 wovbe)\ liauid of coolant. 2 ... he switched off before the sAstem had 3 ... the engine on one of the corners. with dirt. 4 ... the openings in the side pods alwags 5 The tAres weren't close to 6 ... the radiator problem didn't cause the engine to -
d
)s.z tisten again and check your answers to Exercises 3b and 3c.
e
Read the following comments made by race team technicians.Complete the following sentences using the correct form of words in Exercises 3b and 3c. I There'ssmoke and flames pouring out of the engine.;1'5 blow\ qP 2 There'sa pool of oil under the car. Something's . 3 This cylinderhead bolt won't loosen.lt's 4Theairfi|ter'sfu||ofdirt.|t'scomp|ete|y-. 5 This wing support'sbeen movingabout. The bolts have 6 Something'sstoppingthe oil flow The pipe might be 7 Are you sure that pushrod'sstraight? lt looks as if it's 8We'||needtochangethesebrakepads.They'renear|y-. 9 There'shardly any fuel left in the car. In another lap, we'll
.
Read the technical facts about the ltalian motor racing circuit, Monza, and summarise how the track is different from most others. ln pairs, discuss the technical problems that racing cars could have at Monza as a result of the factors described in the text.
Parabolica
t StarVFinish
Thecircuitis characterised Thismeans thecars'engines bylongslraights andchicanes. percentage mostother Íorover75%ofthe|ap, a higher than circuits. areatÍu|| thrott|e heavier-than-average Thetrackrequires braking overa givenlap,asthecarsrepeatedly íastesl Íor theslowchicanes. dece|erate attheendofsomeoftheworld's straights forfastlaps. Thechicanes kerbs. Riding overthese hardis crucial arelinedbyrugged Thismeans loweÍ downÍorce' The|ong straights require sma|| wings Íorminimum drag. griponcorners resulting overbumps. inlower andunder braking, andlessstability Themainhigh-speed 2 andfurabolica areall rightturns. corners Lesmol, Lesmo Parts bytrees, which means leaves canbeblown oflhecircuit aresunounded ontothetrack.
? Chicane Rettifilio
l" Lesmo2
lr
rl . a ',-1
{f}
Chicane Della Roggia
Unit 5 Breakingpoint
39
fautts Assessingandinterpretíng
r 5
á
|n pairs, discuss a technical problem you've experienced with a device, equipment or vehicle. Describe the fault, and how you tried to solve the problem. Read the training notes for telephone helpline staff working for a manufacturer of mining plant. ln pairs, discuss what each point means. ?'ob /em-so /ving check/is t /
User s observattons.' - nature oí fau/t - circumstances of fau/t - externa/ foctors
2
Process of e/imination /dentiív the íai/ure Determine action and urqency
3 4
6a
)S,l fUr Rooney, an engineer at a quarry firm, is talking to Al, a helpline consultant, about a technical problem with a diesel engine. Listen to the conversation and answer the following questions. I 2 3 4 5 6
What does the warning messagesay? What externalfactor is discussedas a possiblecause? Why is this possiblecause eliminated? ln what circumstancesdoes the fault occur? What does the consultantidentifyas the most likelycause? What action is required,and how urgent is it?
Match the words in the box to their synonyms in the sentences (l-7). defect defective fut I
2 3 4 5 6 7
There's a problem.
fautty intermittentty major minor property systematicalty latqlt
I-
Perhapssomething in thefuelinjection systemis wrong.lt'sa seriousproblem. lt'sa slightproblem.ls it workingcorrectly? The problemonlyoccursfrom time to time. The problemdoesn'toccureverytime.-
I
C Al made the following notes about three engine problems. Match the faults
(l -3) to the possiblecauses(a-c).
I Siartormotoraometimos vrorKs, somo'times doesn'i. ongineis í 1earsold. 2 Dietribution boltfailed.tngineblevr. be|t replracYó recently almostnew 7 Nswengine. Runsfqr 2o mina,ihcniemp.gaugoalwals goesintored,and enginecultout(safe\override) 40
point Unit5 Breaking
problem. a holing a1s'tem Fan?ulaterpump? b O\ectrica\ conlaclproblom l-ooseconncction? c Manufacturing dcÍYcil lncorrYclfitting?Noi wear
I d In pairs, describethe problemsin Exercise6c usingthe followingphrases. a fuuttypart a suddenproblem a systematicproblem an installatión prgblem an intermittentproblem causedby wearand tear Ifs / It was ... It's / It was probably... Perhapsifs / it was ... Thisis / wasa ...
e
Complete the following table using the phrases in the box from the conversation. I doubtifs
it can,tbe it couldbe it mightbe it:mtstáe it soundslike iÍs
be 1 Iís certain|.y 7 it t^l'^st 2 Iís probab|.y /3 I t s p o s s i b L/ y- / not/ 4 Ifs probabl.y 5 Iís certainlynot/ -
7
-
a probtemwith...
f
)S,l Complete the following extracts from the conversation using phrases in Exercise 2e. Listen again and check your answers. 1 Obvioustg, it mqsf be some sort of defect in the fuel iniection sAstem. 2 So a software problem. 3 ... magbe a defective sensor. 4 Presumablg, angthing too serious. 5 water, then, if the fuel went in directlg from a deliverg. 6 a faultg fuel pre-heater.
a
In pairs, analyse the problem described below. Underline the words in the box that describe it. major minor sudden systematic intermittent
The problem Thedriverof a dumptruck,whichoperatesin a quarryhas noticedthat the truck'sdieselengineis slightlydownon power.The problemhas become progressively worseoverseveralweeks.Apart fromthe powerloss,the engineis performing consistently, withno misfiringand no overheating. The degreeof powerloss remainsconstantthroughouta givenperiodof use, from startingthe engineto turningit off. No increasein fuelconsumption has beennoted. Read the notesand assessthe possible causes of the problem in Exercise7a using the words in Exercises6d and 6e.
?ossiblecdffies0f the engineProblern . wdterin thefuel supply ' a lubricationProblen ' a cloggedfuel filter , a blockagein the exhduitll;tem o d cornPres,i\nle^Kfr1m the piston qlinders
Unit 5 Breakingpoint
47
I
DescribÍng the causesof faults 8
Look at the following strategies for preventing and dealing with technical
problems in aviation.ln pairs, discusswhat is meant by the following terms and how they are used by engineersand pilots. I 2
9
checklists standard procedures
3 back-upinstallations 4 p l a n n e dm a i n t e n a n c e
a Read the articleon the right and answer the followingquestions. I Howdid the problemstart? 2 Whatwerethe initial,unseen consequences? 3 Whatwerethe subsequent conseouences?
b
Complete the sequence of events that followed the fuel leak on the Airbus
A330 usingthe extracts (a-d).
Ül:]B rrre flightdata recorder registeredan abnormalincrease in fuel consumption.At this stage.howeve[ this slight anomalywas insufficientto cause warning lightsto come on to aleft the crew to anv imminentdanger. ilS:ll n warning message came up. alertingthe crew to an ímba|ancebeNveenthe amountof fuel in each wing tank. Initially. the problemwas thought to be an instrument malfunction.But furtheranalysis bv the crew revealedthat the
"We have a problem"
Thetruestoryof AirTnnsat Ftight236. tT,h.
chain of events began during routine maintenance I work on an Air Transat Airbus A330. An incorrect hydraulic pipe was fitted to the right-hand engine. The component was oversized, leaving inadequate clearance with an adiacent fuel line. Subsequently, the two pipes rubbed together, causing the fuel line to wear progressively. The problem went undetected, until the night of August 24,2001, at 35,000 feet above the Atlantic. !(rith Flight 236 en route from Toronto to Lisbon, carrying 30ó people, the fuel line ruptured, resulting in a major leak. Less úan two hours later, the aircraft was completely out of fuel, gliding silently through the night sky . . .
amount of fuel remainingin the right tank was significantly below the planned quantity. 05:tl5 ,qsa precaution.the crew decided to diveftto the nearest airport- the Lajesmilitaryairbase in the Ázores. ÜE:dE rruc 2 FAILappeareo, and the leftengine cut out. Having completelyrun out of fuel,and with both engines now down, the AirbusA330 was gliding.descendingat 2.000 feet oer minute.
An alarm sounded, a red masterwarning lit up and the messageENG I FAILcame up on the screen.Secondslatet the right engine flamedout due to insufficientfuel. b During a routineinstrumentcheck,the crew noticeda disproportionate amount of oil had been used by each engine. Oil pressureand temperaturereadingsfor each engine were also irregular,but the levelswere found to be within acceotableoarameters.
a
42
I
Unit 5 Breakingpoint
116:ll ÜE:lE, witrr the airportin sight,the landinggearwas lowered manually.The pilot then performeda seriesof spectacuíar z|9za9manoeuvres to slow the plane down as much as possible.The aircraft touched down on the runway at 370 km/h - exceedingthe standardapproachspeed by over 100 km/h.The pilot applied emergencybraking. causingseveraltyresto blow out and catch fire.But the plane stopped safely.well before the end of the runway.
As the aircraftwas now powerlessand potentially uncontrollable,an emergencyram air turbine was deployedautomaticallyto generateback-up electricalpower for the fly-by-wire controlsand instruments.Howevel with the main hydraulics shut down. the flapsand spoilersused to slow the plane beforeand afterlanding were inoperable. The co-pilotcalculatedthe plane could remain airbornefor 15-20 minutes.and that l-ajesairbase was an estimated20 minutesaway. The crew decided to takeaction to correctthe anomaly,opening a cross-feedvalve to transfer fuel from the lefttank to the riqht tank.
T
C
Make opposites of the following words using the prefixes in the box. ab- dis- im-
I 2 3 4 5 6 d
in- (xa) ir-
correct undersized adequate detected normal sufficient
irrcowecf
mat- over7
I 9 l0 ll
unproportionate regular balance function operable
Complete the following sentences using the words in Exercise 9c. Sometimes more than one word is possible. lThetemperaturegaugeWasfau|ty.That'swhyitwasgivingreadings. 2 The shaft was thinner than it should have been, so its strengthwas
3 The poweroutputfromthe motorvaries.We don't understandwhy it's 4 The bolt's . lt's too big to fit into the hole. 5 Themachine'snotworkingasitshou|d.There'ssomekindof-. o
8
0
The braking force on both front wheels should be the same.There shouldn'tbe an_. ThefaultWas-.Noneofthemaintenancetechnicianshadnoticed it. The control panel isn't working,so you can't control the machine.lt's totally
a )S.l Julia, an aircraftservicetechnician,is phoningAlan, a colleague,about a problem with the tyres on a plane. Listen to the conversationand mark the statementsTrue O) or False (F). I Thetyrepressures on the blockbeingdiscussedare OK. 2 Thereis too littleair insidesomeof the tyres. 3 The tyre pressuresare the sameacrossthe aircraft. 4 The degreeof wearacrossall the tyresis the same. Complete the following sentences using words in Exercise 9c to make true sentences about the conversation.
I Thetyrepressures on the blockbeingdiscussedare-. 2 Thereis air pressureinsidesomeof the tyres. 3 Thetyrepressures on that blockare to the restof the aircraft. The wearrate is acrossall the tvres. ln pairs, discussthe possible causes of insufficienttyre pressure in general,and the specificproblem Julia describesin Exercise 10a, and say why each general cause you discussedis likely or unlikely in this case.
I
Discussingrepairsand maintenance tta
In pairs, discuss the difference between repairs and maintenance and declde whether the following words relate to repairs, maintenance or both. broken ctogged defective fautty worn
b 72a
!n pairs, compare car maintenance with aircraft maintenance.Which aspects are quite similar and which are very different? Match the content sections (l -10) of an aircraft service manual to the descriptions (a-j).
Contents I 2 3 4 5 6 7 8 9 l0
b
Openingand dismantlingaccesspanels Toppingup, drainingand replacing coolantsand lubricants Replacingfilters Safely isolatingelectricalcomponents Safely disconnectingand reconnecting electrical components Mechanicalconnectionsto be checkeÜ tightenedat each service Parts susceptibleto wear/damage,to be examinedat eachservice Sensitivedevicesto be adiustedat each service Informationon non-serviceableparts / sealedunits Tableofcomponentlife spans
! ! ! ! ! ! ! ! !
a b c d e
Switchingoff the power supply Making sure certain parts haven'tworked loose Changingparts that can become clogged A d d i n ga n d c h a n g i n gf l u i d s Equipmentthat needs to be set up precisely
maintenanee Takingparts off and refittingthem without danger h Componentsthat can't be repairedon site i Detailsof how long parts are designedto last j Making sure parts are still in good condition g
Match the verbs (l-lO) from Exercise l2a to the definitions (a-j). 1 2
adjust drain
3 4
disconnect dismantle
5 6 7 8
examine replace reconnect
service 9 tighten 10 top up
44
nrl LEJ
Unit 5 Breakingpoint
carryout plannedmaintenance part changean otdor damaged checkcarefutty emptya tiquid e addmoreftuidto fitt a tankto the recommended level f set up carefully by makingsma[[ changes components Í1 takeapartassembted h apptythe correcttorque,for exampte to loosebotts i establish a connection again j removeor isolatefroma circuitor network a b c d
13a
)s.s n service technician is examining some machinery and talking to a colleague. What does he say about each point on the maintenance checklist?
ervance l4aínt ClwcL|tst
1 2 3 t+ 5
Caalp.nttawL Caalp"wt canlítían Caa|n,wt fi,Ltcrcanlítían BLal,owenr/da,rrr,qe BLala aLr,gnruwt
)s.S tisten again. Do you think the technicians are working on an aircraft or on an industrial machine?
c 74a
ln pairs, discuss what maintenance needs to be carried out on the machinery in Exercise | 3a, describing the operations step by step. You work for IPS, a producer of industrial packaging machinery.As a member of the global service team your role is to travel abroad dealing with serious technical problems at your clients' plants. Read the following email from a plant in Helsinki and summarise the problem. To Chris McLean SubjeclF orkliftdamaoe to lPSl5 Helsinki
truck has hit Fo||owing our phone conversationthis morningI confirmthat a Íork|ift our lPSl5 unit.The impacthas made a largeholein the mainpanelon the side oÍthe machine.our technicianwho is trainedto carryout routineadjustments on the machinehas made an externalvlsualinspection.He has advised me that the mechanismsfor adjustingthe precisealignmentof the cuttingblades have been damaged.Liquidlubricantis also leakingout fromunderthe machineand a cracklingsound can be heardinsidethe unitwhen it is switchedon - presumably resu|tingÍrome|ectrica| damage. due to ear1hing/short-circuiting by your serviceteam' I conÍirmmy requestfor intervention
ln pairs, describe the sequence of steps you'll need to take to carry out repairs when you arrive in Finland, using the notes to help you.
75
Think back to some repairs or maintenance you did, or had done for you, in the past, for example on a car, bike or domestic appliance. In pairs, explain what servicing or repairs were required, and the main steps involved in carrying them out.
lPs ls HelsihLi e i\tev\arl )totuatge e ol/ garrfs r elec|ricarl srapgly: our/ o€ € r ltabvicai\t: i\ ,/ oqt r extevrrarl gartrels e atligruaert oP craftitg e test e \ew Pavfs
bla/res
Unit 5 Breakingpoint
45
UNIT 6 a a a
E
Discussing technicat requirements Suggesting ideasandsolutions Assessingfeasibitity Describing improvements and redesigns
90
,-t
Discussing technicalreguirements What is needs analgsis? ln pairs, discuss why the following factors are important in needs analysis, giving examples of products and installations. budget capacity dimensions tayout looks performance regutations timesca[e
2a
)O.t Clauaia, an engineel is asking Kevin and Dave, the managers of a fun park, about their requirements for a proposed space module simulator called Mars Lander. Listen to the conversation and note the three main areas Claudia asks about.
)tf How do Ctaudia and Kevin focus on specific subiects? Complete the following phrases from the conversation using the words in the box. Listen again and check your answers. concernedregard regardingregards terms 1 2 3 4 5
to the capacitA,... ... with ... in of the number of people ... ... as far as size is ... And os the graphics ... . . .t h e s c h e d u l e. . .
Write questions using the following prompts and the phrases in Exercise 2b. I dimensions: what / overall size / module? \,ith vqgotv)'fo fhe /,ir^,rerrsiorrs, what| is the overatll size o| |he wroáqle7 2 materials: what I bodywork I made of? 3 s c h e d u l ew : h e n/ w o r k s f a r t ? 4 power:what / maxiirum output I needI be? 5 heat resistance:what sort / temperature/ paint / need / withstand? 6 tolerance:what level/ precision/ you want us / work to? 46 T
Unit 6 Technicaldevelopment
I
I
a )O.Z Claudia goes on to ask about the physical effects the simulator needs to produce. Listen to the conversation and make notes on the following points. I 2 3
Possiblevariationin simulatormovement Extent of physical effects required Best way to assess physical effects
)O.Z tisten again and exptain what is meant by the words and phrases in bold. 1 2 3 4 5
... to what extent do gou wont the experience to be phgsical? The degree to which it moves can be varied ... ... tfb obviouslg difficult to quantifg something like this ... The onlg wag to determine what's right is to actuallg sit in a simulator ... ... gou con ossess the possibilities.
Following the meeting, Claudia writes an email to update Rod, an engineering colleague. Read the extract and choose a word or phrase from Exercise 3b that means the same as the words in bold. Sometimes more than one answer is possible. To: Rod Nelson Subiect: Mars Lander
Inorderto (]) Í.ndout about the simu|ator's we |ookedat the dynamiccapabilities, typesoÍeffectthe simu|ator shou|dproduce'and (2)the amount thesephysica| issueswerediscussed: effectsshou|dbe Íe|tby passengers'SpeciÍical|y' theÍol|owing - (3)How severely shouldthe modulegeneratevibration, to simulateenginethrust? - How muchbuffetingshouldbe simulated?Thatis, (4)how severely the module generatesjolting,due to supposedatmospheric turbulence. - (5)How much willpassengersbe exposedto constantlinearGJorce,to simulate deceleration? |norderto (6)work out the magnitudeoÍtheaboveparameters, it was decidedthat the prototype willbe equippedwithvariablecontrols.Thiswillenabletheclientto (7)eva|uatedifferent |eve|soÍseveritythroughtria|sinsidethe simu|ator' -a-t
4
I
,rSSeSS
2_ 3 4
You are consulting engineers preparlng to work with a space agency to design an unmanned landing module. The module, which will carry scientific equipment, is intended to detach from a space ship orbiting Mars and land on the planet. At this stage, this is all you know about the project. In pairs, prepare a list of the main questions you will need to ask at the needs analysis meeting using the following ideas. . type of scientificequipment o size/weightof equipment o solidity/fragility of equipment o surfaceconditionsat landingsite
Unit 6 Technicaldevelopment
47
Suggestingideas and solutions In pairs, discuss the following questions about creative thinking. o What are the most effectiveways of coming up with ideas and finding ingenioussolutionsto technicalproblems? o What do you think of brainstorming- generatinglots of ideas randomly in a group session, without analysis initiatty,then subiecting each idea to analysisand criticismas a second phase? o What do you think of evaluatingideas progressively- continuallysubjecting them to analysisand criticism? o When creativethinking is requiredto solve problems,what are the pros and cons of working individually,in small groups,or in large groups?
)
6
a
Read the newspaper articte and answer the following questions. I How is the statue being made,and what is it being made from? 2 What is Rick Gilliam'srole? 3 What will the statue be placed on in its final positionin front of the museum? 4 What technicalproblem did they have to solve?
T
tTh"
new statue outside the I Museum of Natural History has been a mammoth project, literally. The soon-to-becompleted sculpture portrays a life'sized woolly mammoth, carved from a sing|e block oÍsandstone. Initially, one aspect of the project had engineers baífled. Rick Gilliam, the engineer overseeing the logistics, admitted that he and his colleagues had fried their brains trying to figure out how the 36-tonne monster could be lowered onto the stone plinth that will support it. 'We knew that we could put slings under the base of the statue, and pick it up with a crane,' he explained, and that transporting it from the stonemason's vard on a lowJoader wouldn't be a problem. 'The problem is placing it on the flat plinth prevent you that supports it. How do getting the crane's slings from trapped between the base and the plinth, so that
48
Unit 6 Technicat devetopment
they can be withdrawn? We couldn't think of an easy way to do it.' The creative answer eventuatly came, not from the engineers, but from the stonemasons, who had affectionately been nicknamed the 'cavemen'.
b
Rick is talking to Gabriella, an engineering colleague,about the problem of placing the statue. Before you listen, explain what is meant by the following terms and try to guess what the three possible solutions are. bar dritt friction a grab(onthe endof a cranejib) horizontal lifting eyes resin verticat
C )O.g Listen to the conversation and summarise the ideas. How do their ideas compare with yours? Why is each suggestion rejected? d
Complete the following suggestions from the conversation using the words in the box. about atternatively another coutd couldn't don't not \ot Whg Well, We Or, What I suppose of the crane jib. Whg
1 2 3 4 5 6 7 g
come up with a wag of hooking onto the side of the statue? we drill into it, horizontallg ...? fill all the holes, couldn't we? , we could mal:e sure the holes were out of sight. drilling into the top, verticallg? option would be to use some sort of grab, on the end we ask them?
You are engineers working on the mammoth statue project, with the following technical requirements. ln pairs, discuss possible solutions to the problem of placing the statue on the plinth using the phrases in the box. Alternatively Anotheroptionwouldbe ... Couldn'twe ... W h a ta b o u t . . .? W h yd o n ' tw e . . . ? W h yn o t . . . ?
We could ...
No holes, s|o|s ov gvoTves w.otybe cut ih |he s|at|qe. fl|l o€ i|s sh'€aces mhs! vematih iht,rc|. NT sP,rcevS l,q,rYbe le€t belweeh the qtláevsiáe o* |he star|ue,s {lar| barse au/ the +lat h||ev J[av|a16eo€ |he glirr|h. Íhe two sh'Paces mus| be le{t i\ áivec| co\t,rc| with earch olhev. o ÍÁe startqe u,rl^s|lrot be srabjec|eá |o shocks. Sra/áe\ ),vols, evelt oQ ar €ew u.rillimetves, atve oht o* |he qqes+io\ giverr |he *vargility oP the sch|PtqY€/ especiatlly art its covhevs at\á e)tgeS, which cort\be ),ov,tage), eatSily. , A'ly accessovy eqrriguaerr|u,ratybe raseá, withitt the liprits o€ tech'ricarl possibi|it7 atrrá rearsotlrrble cost
l ,
The stonemasons suggested a solution to the statue problem. Read their idea on page 99 and compare it with your solution. What external factors could cause some problems with their idea? How could these be solved?
Unit 6 Technicaldevetopment
49
Assessingfeasibitity 8
a
In pairs, dscuss what is meant by feasibilitg.
b
Look at the flow chart and, in pairs, discuss how budgets and schedules affect the technical feasibility of design, development and manufacturing solutions. Size of budget A bigger/smallerbudget often means ... L e n g t ho f s c h e d u l e A longer/shorterscheduleoften means ...
9a
Technícal feasibitity design. ... more/lesssophisticated/innovative lity/efticiency. ... higher/lowerquality/reliabi
)s.l vit toa an engineerfrom a German companythat makesand installsindustrial gantry cranes,is phoningRaiesh,the constructionmanagerof a manufacturing plant currentlybeingbuilt near New Delhi, lndia. They are discussingthe gantry crane due to be installed at the plant. Listen to the conversationand answerthe following questions. I Whyare holesneededin the concretewalls? 2 What are core drilled holes and what are preformedholes?
ln this context,what is meant by plag? What impact will the lack of play around the bolts have (on the construction)? 5 Apart from technicalquestions,what two issueswill determinethe most feasibleway of formingthe holes?
3 4
ln pairs, compare core drilling and preforming with regard to the following feasibility issues. Which technique is most suitable for the situation in Exercise 9a?
ü:
fr
cost
precision ümescate
)O.S Viftor and Rajesh are assessing the most suitable method of forming the holes in the walls. Listen to the conversation and compare their answers with yours. )o.l tisten again and answer the following questions. I What are the advantages of using preformed holes in terms of cost and timescale? 2 What's the main disadvantageof core drillingthe holes? 3 What tolerance can easily be achieved with preformed holes? 4 What tolerance is required for the holes on this project? 5 What's the risk of using preformed holes? 6 What key feasibility issue does Rajesh identify?
50
Unit 6 Íechnicaldevetopment
I e
Complete the following expressions from the conversation using the words in the box and indicate the degree of feasibility each expression describes. borderline dcad forever teg painstaking peanuts perfectl.ystretching.tatt way
1 2 3 4
AeaA it,tlbe 2g5g it'ttcostit'llbequitea-job it's-feasible
it 5 it's achievable, but it's do it 6 there's no can Aou -l it's 8 if's o -order 9 it'lltake 10 it'll cost an arm and a f
@-e @l Ú tr ! tr
!! !l !! !!
! D ! !
trtr !!
tr ! tr !
tr
feasible but challenging
o o
completety unfeasible
@
perfectly feasible
! ! !
! !
How feasible do you thing the following suggestions are? Label ttrem @ Q or @ according to the key in Exercise 9e.
1 The machineparts are tricky to paint with brushes,or to spray.Why don't we dip them in paint? 2 The steel bar is lOOmm in diameter.Couldn'tit be cut by hand, using a hacksaw? 3 Silver'sa good conductor.Why don't we use it for wiring, instead of copper? 4 Insteadof puttinglead ballastin the heliumballoonbasket,why don't we use water containers? 5 They'veused the wrong type of fuel in the engine.I'd suggest stripping the whole thing down and cleaningit by hand. 6 They produce6,000 units per day and normallydo a qualitycheckon l0loof them. Couldn'tthey checkeverysingleproduct?
g 10
ln pairs, give an appropriate response to the suggestions in Exercise 9f using the expressions in Exercise 9e. In pairs, discuss the feasibility of the following solutions to the problem of forming accurately positioned holes through the plant walls in New Delhi. Student A, you are Viktor; Student B, you are Rajesh. Discuss technical issues, cost and timescale, and rank the solutions in order of feasibility. I
2
3
4
ls a diamond drill really needed to go through reinforcedconcrete?Surely you can drill into concretewith an ordinarv hammer-actiondrill? Wouldn'tthat reducethe cost? Couldn'tthey make the preformedholes wider than required,so there'sextra tolerance?Then, once the bolts are fixed, the space around them could be filled with cement. Why not drill the holes in the steel beams on site, instead of pre-drilling them? Then they could be positionedto suit the locationof the preformed holes in the wall. That way,it wouldn'tmatter if the holes in the walls were slightlyout of position. Insteadof boltingthrough the concrete,what about adding extra steel columnsthat run down the walls? The beams could then be supportedon these,and no holes would be requiredthroughthe concrete.
Unit 6 Technicaldevelopment
51
Describingimprovements and redesigns Look at the slide from an engineers'trainingcourse,TotalTechnical lmprovemenÚ.|n pairs, suggestexamplesof technica|improvementsto illustrate each one. Are there other points that could be added to the list?
t2
it Look at the slide from a design meetingat a computerprinter manufacturer.ln pairs, suggestways that the followingprinter factors might be improvedin some of the areas on the list. cables/connections case ink/toner cartridges papeÍ poweÍ software
Pccolble
oneoe Íor improvemonÜ
I Aesthetics 2 User interfoce 3 Reliobility 4 Gonsumobles
5 Outpur quolity ond speed ó MoinÍenonce 7 Monufocturing I Environmentql impocr
'LO.O
ft4".t", a manager at the printer manufacturer, is briefing the design team on key requirements for the redesign of a printer. Listen to the start of the meeting. Which two areas on the slide in Exercise l2a are discussed? )O.O tisten again and answer the following questions. I Should the layoutand componentsof the new printer differ much from the existingdesign? Why (not)? 2 How many times has the existingmodel been improvedin the past? 3 What considerationis behind the decisionon how differentthe new software s h o u l db e ? 4 To what extent should the new software system differ from the existing one? Look at the following verbs from the discussion and find three examples where re- means again. Match the other three verbs to the definitions in the box. improveoverall improvethe details stay(thesame) I 2
52
redesign áesiqrr arqarirr reinvent
Unit 6 Technicaldevelopment
3 refine 4 revamp
5 rethink 6 remain
)O.O Complete the following expressions from the discussion using the words in the box. Listen and check your answers. Achil.tes back dnwingboard ground heel improvement leap quantum rcinvant room scntch up whct veirrve\f wheel 1 the 2 designing the whole thing from the
4 the 5
for
to the 6 make a 1 designing the sgstem from
Match the expressions (l -5) in Exercise l2e to the definitions (a-0. a waste time re-creatingsomethingthat has already been created I b the biggestweakness c start again becausethe first plan failed d make huge progressIe design from the beginning job potential for f doing a better Rewrite the following sentences using the correct form of the expressions in Exercise l2e. 1 Unfortunately,we had to scrap the conceptand start again. We hará |o qo barclr |o |he ztvarwir,rq boav).. 2 This problem is the product'smost serious shortcoming. 3 There'sno point redesigningwhat alreadyworks perfectlywell. 4
lt's a totally new design - we started from the very beginning.
5 The new design is so much better - it's a transformation 6
.3a
I
I think there'sdefinitelya possibilityto do better in this area.
!n pairs, discuss how computer pointing devices have improved since the first mouse was invented. Use the language from this section and the words in the box. batt buttons first mechanicalmouse optical mouse optical sensors refinedmechanicalmouse sensitivesurfuce touchpad wheel wiretess
You have been asked by a computer hardware manufacturer to think of some functional improvements and technical solutions for pointing devices. ln pairs, discuss your ideas.
íQrEffi
Present your ideas in Exercise I 3b to another pair.
Unit 6 Technicaldevelopment
53
UNIT 7 Describingheatthandsafety precautions Emphasising the importance of precautions Discussing regulations and standards Workingwith written instructions andnotices
Describing healthandsafety
n
precautions
tl
Some engineering or industrial activities are especially dangerous. ln pairs, think of more examples to add to the following list. o e
2a
M a n u f a c t u r i n gp r o c e s s e su s i n gd a n g e r o u sc h e m i c a l s C a s t i n ga n d w e l d i n gi n v o l v i n gh i g h t e m p e r a t u r e s
ln pairs, discuss what is meant by the items on the Health and Safety meeting agenda.
b
)l,t Rosana, the assistant manager at a Dorian Food Processing plant, is chairing the weekly Health and Safety meeting. Listen to four extracts from the meeting and match each extract (a-d) to an agenda item (l -7). a_
c_
Dorian Food Processing Health & Safety Meeting Agenda
Wednesday ló April, Conference Room, 2.00pm - 4.0C To: Chair: I 2 3 4 5 ó 7
RM, MA, DB, SM, BP, LJ Rosana Martinez
Hazardoussubstances& Personal ProtectiveEquipment Harmful gases/fumes6 asphyxiation hazards Fire/Explosionhazards Machinery: guards and safetydevices Access ways, guardrailsand emergencyexits ElectricaIinstallations Noise hazards
)l.t Listen again and match the words from the meeting (l -8) to the definitions (a-h). 1 2 3 4 5 6 7 8
54
L
confinedspaces C0, detector exposure irritant toxic corrosive flammable naked flames/sparks
a b c d e f g h
burnsthe skin contact (with a danger) sourcesof ignition small areaswithoutventitation measurescarbondioxide poisonous causesskin to react catches fire easily
Unit 7 Procedures and precautions
Which four types of PPE shownin the photos are mentionedat the meeting? In pairs, discussthe hazardsin the followingsituationsand the precautions that should be taken. I Workinginsidea containerwithlimitedair circulation 2 Cleaningmetalusingacidthatcan burnthe skinand whichgivesofffumes 3 Usinga grinderto cut througha steelplate 4 Applyingpaintthat cancausepainfulrasheson the hands
3a
Stephanie,Dorian's senior safety officer,is attendinga meetingon standard procedurefor some engineeringwork that will be carried out at severalof Dorian's plants around the world. Before the meetingshe made notes. Read her notes and answerthe followingquestions. I What is meant by hazard Hazardanafusts & safesptenoft^rorL. analgsis? 2 What is anotherwayto saysafe }peratÍsn: t4aínten'a,we, tagraínsíhs sAstem of work? ínva|,víltg weaíng(ufthary-ar,etgb'w) 3 Whattype of work is goingto be kcat isnlInterínn carriedout, and where? a( enptgsíks(apprar 4 What is meantby accessto 3n dínrwter r,|5n daep), at battans silos? f[aínsa|etgíssws:ilcussta sihsforr.,orters 5 Whatare the specifichazards relatingto confinedspacesin & quípwnt' Can!íwd, spoa hnzards thissituation?
b
.'G-,
U
b )l: Stephanieis discussingsome of the hazardswith Ben, one of Dorian's engineering managers. Listen to the conversation and note the hazards that they mention. I Access hazards:
2 Confinedspacehazards: C )lf Listen again and answerthe followingquestions. I What safetyprecautionsare discussed? 2 Whichprecautionmightmakeone of the hazardsworse,and how? In pairs, discuss suitable health and safety precautionsand PPE for the following operations on an existing steel petrol storage tank at a processingplant. StudentA, you are a safety officer;Student B, you are an engineeringmanager.Use the phrases in the box. Swap roles and practise again. a An openingneedsto be cut throughthe wall. o A newsteeloutletpipemustthenbe weldedontothe opening. a The existingpaint mustthen be removedfrom the externalsurfaceof the tank,by shot-blasting. The tank mustthen be repainted. Themaindanger/hazard is . Anotherdanger/hazard is ... There's a riskof... -ing
They'tL haveto takecarethat ... haveto be (very)caretul... They'l.t Tobe safe,they'tl.needto ...
Unit 7 Proceduresand precautions
55
Emphasising the importance of precautions a Dorian Food Processingis currentlystandardisingsafety proceduresat its plants around the world. Read the followingextract from the contents page of the company'snew safety documentationand answerthe following questions. I Whatis meantby LV and HV electricalmaintenance operations? mightbe carriedout in a factory? 2 Whatkindsof electricalmaintenance LV &HV ELECTRICAL MAINTENANCE OPEMTIONS Part I Identifying and designating Restricted Areas (switchboards, transÍormerstations, areas with exposed conductors) Part 2 Authorising maintenance - The role of the Electrical Supervisor - Procedures for issuing Permits to Work Part 3 Isolatingand energisingcircuits - Lock-Out Procedure - Temporary Warning Notices on switchboards
)l.l tisten to Stephanieexplainingthe safety proceduresto Lin, the plant managerin Beijing.What is meant by the followingphrases? I restrictedareas 2 a permitto work 3 the electricalsupervisor 4 the lock-outprocedure )l.l Completethe followingextracts from the conversationby underlining the phrases that give the strongestemphasis.Listen to the conversation again and check your answers. 1 Restrictedareas are places wherea serious danger is present.So it's essentialthat theseshould be kept locked at oll times / all the time. 2 Under no circumstancesshould angone / Nobodg should under ang circumstancesbe able to access them ... 3 ... it's importantthat permits are issued each time / everg single time someoneenters... 4 And it's crucial thot there'sjust one / just a single keg to eoch restricted area. 5 Then,whiletheg'reworking,it's vital / ittsadvisable that theg keep the keg on them...
ll,
lli
Which of the followingphrasesgive more emphasisthan rt3 important,and whichgive less? 3 it's preferable I it'scrucial 4 it'svital 2 it'sessential
56
I
Unit 7 Proceduresand precautions
I
Rewritethe followingprecautionsusingthe phrases in the box to add emphasis. atatFtirrrcs everysingte iís crucial iís essential iís ütat undernocircumstances I Thefire exitshouldalwaysbe keptclear. Íhe s'e exi| shorrla\be kept clearr at| arlltrt.les. 2 lt'simportantto testthatthe circuitis isolated. 3 You should reset the alarm routinelywhen you start the system. 4
lt's a good idea to check that the cable is not damaged.
materialsin It'srecommended thatyou shouldonlystorenon-flammable thiszone. 6
Nobody should enter the restrictedarea without permission.
are tight. the system,makesureall the connections 7 Beforepressurising In pairs, discuss the following basic precautions for working on electrical circuits. During work: Before starting: o lsolate circuitat switchboard o Tightenconnectionsfully o Don't damage insulation o Testcircuit- no current 6
d
To finish: o Check no loose wires o Testcircuit
Read the following extract from an electricity company newsletter. What procedure does the article describe?
power A helicopterhoversbetweenthe toweringpylonsof an extra-high-voltage line.In a cradle,suspendedseveralmetresbelowthe aircraft,standtwo line threadedhot suits.Justa few feetaway men,shroudedin hooded,stainless-steel is a live electriccable,fizzingwith 400,000volts.One of the men,holdinga shortmetalwand,reachesout towardsthe cable.Pockersizedlightningbolts arc throughthe air.Theret no discernibleelectricshock,,iusta slighttingling A lead is thenclippedto the live cable to maintainan electrical sensation. The line men are now on, and connectionwith the cradleand helicopter. work on the live powerline can begin. maintenance In pairs, discuss the main precautions you think should be taken during live line maintenance work by helicopter with regard to the following hazards. I 2 3
Collisionsand snagging(gettingcaught/trapped) Hazards from electrocutionand heat Mechanicalfailure(helicopterand equipment)
)l.l frisaof, an electrical engineer, is describing live line maintenance by helicopter for a TV documentary. What precautions does he describe for each of the three types of hazard in Exercise 6c? ln pairs, think of an operation you are familiar with that requires safety precautions. Student A, you are a safety officer; explain the precautions to a new employee. Student B, you are a new employee. Swap roles and practise again. Unit 7 Proceduresand
tl ll ll
Discussingregulationsandstandards 8
ln pairs, discuss what is meant by regulations and standards, Íor example safetg regulations and design standards. Give some examples of organisationsand departmentsin your countryand lnternationalbodies that produce these kinds of rules.
9a
Offshore oil platformsare coveredby extensivesafety regulationsand design standards.ln pairs, discuss the main hazardsthat oil platform workers face and suggestsome safety precautionsthat need to be taken. )7.5 lsobel, a Health and Safety specialist,is speakingto newlyrecruited oil platform technicianson a training course.Listen to the introductionto her talk and answer the followingquestlons. I Whatkindsof regulation willthe coursedealwith? 2 Whatexamplesdoesthe trainergive? 3 Whatimportantpointis emphasised? Completethe followingextract from lsobel's talk by underliningthe correct words. Thefocus of the course will be on Aour personal (1)legislation / obligations in terms of looking after Aour own safetg,and the safetg of others.Thatmeons we'llbe focusingon specificsafetg regulations.For instance,we'llbe lookingat personalprotectiveequipmentthat's (2)compulsorg/ prohibited. Or activities that are (3)compulsorg/ prohibited in certain oreos,such as smoking.The majoritgof the obligationswe'lldeal with are legal (4)requirements/ permits. In other words,theg're(5)permitted / stipulated bg law as part of healthand safetg (6)legislation / obligation. lf gou (7)contravene/ complg with these kinds of regulations,it'snot the same as turningup for work late, or merelg breachingAour contractof emplogmentin some wag.If someonefails to (8)contravene/ complg with healthand safetg regs, theg'rebreakingthe law. It'sas simple as thot. Ih sure Aou'reall aware of that, but it is an important point to emphasise.
It tr
Completethe followinggroups of synonymsusingthe words in bold in Exercise9c. l i||ega| / banned/ forbidden7 pvohbi|eá 2 allowed/ authorised I3 adhereto / conformto / 4 stated I (regulations) 5 break(thelaw)/ breach(regulations) Ipersonal 6 laws/ regulations I -/ legal-/ 7 obligatoryI -
58
I
Unit 7 Proceduresand precautions
I )
a
Read the extract from a guide to safety in the offshore oil industry. Complete the text using the words you wrote in Exercise 9d. The helicopterflightsthat ferrypersonnelto and fromthe platformare subjectto specific safety (r) legislartiorr. The proceduresand standardsthat are (z) to the followingareas: by this regulationsrelate,principally, o Helicoptersea crashevacuationtraining.Coursesare G) personnel
for all
o Designand safe operationof oil platformhelidecks o S p e c i a l i s e dp i l o tt r a i n í n g . F o rN o r t hS e a o i l p l a t f o r m tsh a tf a l l w i t h i nU K ( + )- , o p e r a t i o nm s ust of BritishHealthand Safety the legal(6)G) regulations,and CivilAviationAuthorityrules.They must also satisfythe laid down by the U K Healthand Safety additionalspecific() Executiveand the OffshoreIndustryAdvisoryCommittee,HelicopterLiaison Group (OIAC-HLG).
b
Read the following notes on the design requirements for helidecks on oil platforms. ln pairs, discuss the possible reasons for these design standards.
'
I
T;:H s }:yí."*ffi
;;::l.r:*
oPlarvges| helicogter
7
f,q7voach/tal.eolP vohtes: ar{iarcerrt stvqclqves he|iáecL - ho t,ill stvhctqves
below level oP
j
Pevir,retev gvofec-Fiorr (fo pveve\f peysohhel fvoua *arllirrg):harta\raril |hart car't be loweveá ov hovieorrtarlrtel - \o $xeA hartávai|s
4
Eqrei7u.rerrt|o co7e with bará wearthe' / poovy!foi|i1': larrráirrg lights arrrá arrrchor goirrts
geviuaetev
.)
Imagine you are training new engineers in your workplace (or a workplace you know). ln pairs, explain the main requirements of some regulations or standards that are relevant to your industry using the following points. . o o o
key legal requirements the kinds of operationthat must comply with regulations practices/proceduresthat are permitted practices/proceduresthat are prohibited
Unit 7 Proceduresand precautions
59
Workingwith wrÍtteninstructionsand notices
I 12
Think of situations where written notices and instructions are used in industry. In pairs, discuss the following questions. 1 What differentkinds of informationdo they communicate? 2 What are the characteristicsof effectivenoticesand instructions?
13a
The following warning notices are from a guillotine for sheet metal and a precision weighing device in a manufacturing plant. ln pairs, discuss whether each notice warns of a problem that could injure workers, damage the machine. or both.
DANGER
IMPORTANT CAUTION
b
guillotine
Na ar*r-*rti*"b|" parts inside. opening pan€ | invaIidatesguaÍantee.
El€ctüut|on dskt ln ercnt of firc usa co2 Üt|ngubhaB onlt|. Do not u$ watal
a
/5\
b
blade before cleaning c
WARNING Taka orc whcn |lftlng mach|n€ . Hmk crane to rcd llÍt|ng GyCr on|y.
Moistu re-sen s itive device. Store in a dry place.
o
e
Look at the first word in each sign and answer the following questions. 1 Which word is only used to warn of a risk of injuryto people? 2 W h i c h w o r d i s o n l v used to warn of a risk of damage to equipment?
t4
d
The following extracts are from the instruction manuals of three of the machines in Exercise | 3a. In pairs, answer the questions (l -6). b In the event of a fire water extinguishers should not be used on this machine as it contains electrical circuits, and can therefore cause electrocution. Only a carbon dioxide extinguisher should be used.
I Why is it unsafeto put water on the machine? 2 What type of fire extinguisheris recommended?
Care should be taken when cleaning below the guillotine blade as there is a danger that the blade may descend. Before cleaning, the control lever should always be set in the Blade Locked position. Protective gloves should be worn during cleaning as the sump below the blade may contain sharp metal off-cuts.
60
and precautions Unit 7 Procedures
I When lifting this machine, it is essential I' that only the two lifting eyes marked in red should be used. No other parts of the frame are load-bearing and must not, therefore, be used as anchor points.
What is the purpose of the items marked in red on the machine? W h a t c o u l d h a p p e ni f t h e m a c h i n ew a s lifted by other parts of the frame?
Why is it important o lockthe guillotine blade? What other danger is there,and what o r e c a u t i o ns h o u l db e t a k e na s a r e s u l t ?
b )l.O Petrus,an engineerfrom a machinemanufacturer,is giving instructionsabout the machinesin Exercise l4a to a client.As you listen, follow the written texts (a-c) and identifyas many differencesas you can betweenthe spoken instructionsand the written instructions.Use the followingideas. 1 grammaticaldifferences 2 use of contractions 3 differencesin wordsused a Read the followingspoken explanationsof the operatingprecautionsfor an industrial blower.Rephrasethem as written instructions,makingchanges based on the differences between spoken and written language style you identifiedin Exercise l4b. You shouldn'tp|aceobjectsin ÍrontoÍtheair in|et.And you shou|dkeepthe in|etgri||efree Íromobstructions, |Íthere'sdamageto the in|etgri||e, and c|eanit regu|ar|y. stopthe b|ower immediately. Foreignbodiesenteringthe ductcan causeseriousharm,becausethe unit partsrevolvingat speed,so it'shighlysusceptibleto damage. containsprecision-engineered
obiecfs shorela\hot be plotce), irr Qvorrto* the arivirrlet
BeÍoreyou startthe b|ower'it's importantto ensurethatthe e}terna|Ventsat the end oÍ the air-intake ductare open.Whenyou openthevents,Íu||y extendthe adjustinghand|e. Thenwhenyou closethem,turnthe handleand allowit to returnundertheforceof the spring.Don'tpushthe handle,becausethatcan strainthe springmechanism,and result in damage.
Ee€ove starvtihq |he b|oweÍ,,..
Think of some safety or operatingprecautionsyou are familiar with for a machineor processyou know.Write one or two paragraphsof instructions, explainingthe main precautionsthat should be taken. !n pairs, explain the safety or operatingprecautionsfor the machlneor process using your instructionsas a guide. Unit 7 Procedures andprecautions
61
lI
Describing automated systems ln pairs, discuss the differencebetweenan automatedand a manual system. What do you think a Building ManagementSystem (BMS) does in intelligent buildings?Suggestsome operationsthat can be monitoredand controlled automaticallyby the BMS in large buildingssuch as offices.
2a
)s.t Roland, a mechanicaland electricalservices(MeE) engineer,is talking to Saskia, an architect,about the design of a new building.Listen to the conversationand answerthe followingquestions. Whatis a keycharacteristic of the clientcompany? Howwillthischaracteristic affectthe buildingdesign? What do you think is meantby presencedetectors? Whatdoes Rolandsayaboutdesignoptionsand howdoeshe describeoption one?
I 2 3 4
)sz Rolana gives some examplesof sensors and controls.Listen to the next part of the conversationand tick the points he mentions. I controlling the electriclightinginsidethe building ! controllingthe amount of solar radiationenteringthe building controllingthe air flowingin and out throughthe windowsof the building controllingthe flow of warm and cool air aroundthe interiorof the building
2 3 4
Match the words in the box to the synonyms (l -5). detect dettctor pick up reading regutate set off trigger
I 2 3 4 5 62
sensor/ áetec|ov measurement Icontrol(adjust)I sense/ I activate | -
|
Unit 8 Monitoringand controt
! ! !
Completethe followingextractsfrom the conversationby underliningthe correct words. 1 Notjust the usual sAstemsthat activate/detectthe lights ... 2 We could use presencedetectorsto pick up/controlother sgstems... 3 ... a presencedetector sets off/sensesthot evergone'sleft a meetingroom -.. 4 ... a temperaturesensorpicks up a positive detector/reading... 5 ... the sensor detects/regulatessunlight,and senses/trigges the blinds ... 6 ... thosesensorsset off/sensea circulationsAstem... -l ... we'd use presencedetectorsand heat sensorsto deted/regulate as mang sAstemsas possible? In pairs, describe the followingautomatedsystemsusingthe words in Exercise2d. parameter system sensor I presencedetector movement lights fire alarm 2 smokedetector smoke roomtemperature electricconvectorheater 3 thermostat weightof a person intruderalarm 4 pressureplate
la
)g.l RolanA and Saskia go on to discuss an alternative control system in the building. Listen to the conversation and answer the following questions. I What assumptionis the idea based on? 2 What design approach might be taken with regard to controls? 3 What is the advantageof this approach? You are in the MörE design team for the new bui|ding project and have received the following email from the project engineer asking for your input. Read the email and, in pairs, discuss what the engineer wants you to do.
a To: LaurenHarvey Subject: Presencedetectors
Could you look intothe practicalitiesof using presencedetectorsfor controllingthe |ightsin differentpafts of the building?We'|l probab|yhave a mixtureoÍdetectorcontrolledsystemsand manualswitches.The questionis, which Wpe of controldo we want to have in each location? (Please see my list below.)A critical issue will be setting the switch-offdelay in differentlocations, i.e. how long the lights remainon afterthe last movement is detected. On my last prolect,we had a lot of complaints fromthe c|ientabout the |ightsgoing ofÍwhi|epeop|ewere sti||in rooms.So can you thinkabout differenttimerdelaysfor differentlocationsin the building? Main locations:open-planoffices,individualoffices,meetingrooms,corridors, store rooms
T,,
I
Prepare notes for a short talk to brief the proiect engineerusing your ideas from Exercise3b. Student A, you are an MörE engineer.Brief the project engineeron your ideas. Student B, you are the project engineer.Listen to the briefingand ask questionsabout specificdetails.Swap roles and practise again.
Unit 8 Monitoringand control
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parameters Referringto measurabte ln pairs, think of monitoring and control systems that are widely used around the home. Discuss how the following parameters are measured and/or controlled in these common domestic appliances. Parameters:temperature pressure time actions/movement Appliances: boilers heatingsystems refrigerators washingmachines
5a
Match the sensor or measuring system (l -5) to the industrial applications (a-e). 1 pressure measurement a 2 temperature measurement b c 3 flowmeasurement d 4 levelmeasurement e 5 processrecorders
b 6a
monitoring the speed of water trave[tingatong a suppty pipe measuringthe [eve[of heat generatedby an exothermicreaction monitoringthe numberof cans movingalong a conveyorbelt monitoringthe amountof ethanolcontainedin a storagetank checking the force exerted by steam inside a vessel
In pairs, think of other uses for the kinds of sensor and measuring equipment in Exercise 5a. )s.l Jochem and Katerina, two process engineers at a chemicals plant, are discussing the monitoring and control systems that will be needed for a new production line. Listen to three extracts from their discussion and answer the following questions. What problem is discussed? What mechanicalsafety precautionis proposed? What issue is discussed? What three parametersrelatedto consumptionare important? To calculatethe parameters,what does consumptionneed to be c o n t i n u o u s l ym e a s u r e da g a i n s t ? Extract 3 f What issue is discussed? g Which two measurementsneed to be taken? h W h a t o p t i m u mv a l u e n e e d st o b e d e t e r m i n e d ?
Extract I a b Extract 2 c d e
b
Match the words ( I - I O) from the discussion to the definitions (a-j). 1 input
64
2 3 4 5
output optimum differentiat consumption
6 7 8 9 10
cumulative rate cycle frequency timesca[e
a b c d e f g h i j
the best / the most effective/efficient how often somethinghappens used the amountof supplies,ffuel the total quantityso fur a specifiedperiod a value often expressedwith per,for exampleunits per hour the exit value,for exampleat the end of a process the entry vatue,for exampteat the start of a process the gap betweentwo values attthe stepsin a process,from start to finish
Unit 8 Monitoringand control
The following specification was written following the conversation. Complete the text using the words in Exercise 5b.
Vessel Bl: Sensor and Measuring System Requirements Two pressure sensors: one located inside the vessel, and a second situated on the pipe running downstream,to enable any pressure (l) ái$Pevet|iarl to be detected. . Data will be recorded as a A flow meter to monitor gas (2) (3) figure (total usage), and as flow (4) , in flow against the litres per second. Note: Software will be configured to log (5)-ofasystemclock,inordertopinpointpeakflowperiods occurring between the start and finish ofa given reaction (6) -, with which they occur. and to assess the (7) Two temperaturesensors: one at the entry point of the vessel, to measure (8)-temperature,andasecondattheoutletpointtomonitor (9)-temperature.Note;Preciseregulationoftheentry reaction temperaturewill be key to obtaining (10) performance.
7a
You and your partner are process engineers working with Jochem and Katerina at the chemical plant. You need to assess the sensors and measuring equipment required for the steam production facility. ln pairs, discuss the requirements using the information in the diagram. Make notes of your ideas.
Steamout (litres/sec) oC
bar
V V
Water
Lev. oC
Waterin (litres/sec) oc
Gas burner or
P r o p a n ei n (litres/sec)
b In pairs, discuss what parameterscan be determinedfor the installationof a heatingcycle using your ideas from Exercise7a. You should assumethat all the measurementswill be recordedagainst a timescale. Unit 8 Monitoringand control
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Discussingreadingsand trends tl ln o lÍ|pairs, discuss the tacf,orsthat fne factors tnat cause ma|ns mains elecfr|c|ty electricity consumpr|on consumption to vary. IJd|Ís'ulscuss b )g.S Helen, an electrical engineer at a power station, is giving a talk to a group of visiting investors. Listen to the talk and note the five factors that influence electricity consumption. I
3_
z
4
5
C Complete the following extracts from the talk using the correct form of the words in the box. decreasefatl increase rise 1 During periods of verg cold or verg hot weother,demand irtcvearses The-indemandisobviousluduetomilIionsofelectricradiators coming on ... 2 ... a keg factor which or demand, is whether or not it's light or dark ... 3 ... on cold, dark, winter evenings,the in demand is significant ... 4 Cenerollg, demand during the week, when factories and offices are operational ... 5 So demand -at the weekend. 6 There can be a sudden when people rush to switch kettles on, or heat up snocks in microwaves, and then a sudden shortlg afterwards.
ll
)S.O Listen to the next part of Helen's talk and answer the following questions. 1 Why does the company often have significantspare generatingcapacity? 2 What ideal situationdoes Helen describe? 3 Why is this ideal situationdifficultto achieve? Match the words ( | -8) from the talk to the definitions (a-h).
lt
1 2 3 4
ll
5 6 7 8
continuous fl.uctuations \ peaksand troughs \ peak demand range band of fl.uctuation bLips continual
a b . d e f g h
maximumpowerrequirementat a given time amountbetweenan upperand lowerlimit withoutinterruption high points and low points on a graphcurve regular and repetitive momentaryrises fottowedby a futt changes,movementsin general zone of up-and-downmovement
Look at the graph showing electricity demand fluctuations over a week in the UK. Find parts or patterns on the graph described by the words in Exercise 8e and analyse the fluctuations. How do they compare with Helen's explanation?
: = o
Day ofthe week {November) Daily peak demand 8pm
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it Read the document on energy saving aimed at industrial plant and facility managers. Complete the text using the words in Exercise 8e.
Dynomicdemondcontrolsystems con be fittedto electricol opplioncesthotoperote o n d u l yc y c l e s i, e . o p p l i o n c etsh o ts t o r tu p , r u nf o r o t i m e ,s h u td o w no g o i n ,o n d t h e n remoinon stondbyfor o whilebeforerepeotingthe somecycle.Heotingond refrigerotion unttsore commonexomplesof power-hungry ihqtoperoteon thisstort-run-stopequipment w o i tb o s i s . Dynomicsystems exploitthefoctthotdutycycleopplioncesdo notrequire (l ) cotifihqohspower.Thepurposeof the systems is to help smoothpowerdemondfor the benefitof electricutilities. To ochievethis,theydeloythe stort-up of theopplionces theycontrolduringperiodsof(2)-'However,on|yminorodiustmentsore modeto timingos, generolly, theopplioncesconcernedcon only be heldon siondbyfor shortperiodsos ihey needto runon o (3)bosis.Butthisstillbenefits electric uti|itiesosithe|pstoovoidproblemotic,momentory(4)-onthedemond curve. Dynomiccontrolswork by detecting slight(5) in thefrequencyof ihe moins ACsupp|y.A|thoughthisvorieson|ywithinoVerynorrow(ó)-,smo||drops in frequencyindícote thotpowerstotionturbinesore workingcIoseto fu||copocity.The dynomiccontrolsysiemcon therefore holdtheopplionceon stondbyfor o shorttimeuntir m o i n sf r e q u e n ciyn c r e o s eosg o i n .
b
Read the text again and answer the following questions. I 2 3 4 5
10a
What is meant by dutg cgcle? What problem is dynamiccontroldesignedto avoid? What sensor input do dynamiccontrolsrely on to allow them to function? What does the sensor input in (3) indicatewith regard to power stations? To what extent do dynamicsystemsmodifyduty cycles?
Read the extract from the talk and, in pairs, discuss the foilowing questions. ... electrical charge is extremelg difficult to store in large amounts, Aou con't just charge up huge batteries. So we use an innovative technique to store up power potential during off-peak periods. I Why do you think this is such a major issue for power stations? 2 Can you suggestwhat innovativetechniqueis used to solve the problem? )g,l Helen goes on to describe the solution to the problem. Listen to the talk and make notes on pumped storage. Prepare a short talk on the operation of a pumped storage hydroelectric power station for visitors to the power generation company. Use your notes from Exercise lOb and the words in the box. Student A, you are an electrical engineer; Student B, you are a visitor on a tour of the plant. ln pairs, give your talk and ask and answer questions. Swap roles and practise again. graüty
high level.
low [eve[
mountain
pumps
reservoir turbines
Unit 8 Monitoringand control
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tI I
Giving approximatefigures 17
a
Read the email extract and answer the following questions. I 2 3
W h o d o y o u t h i n k s e n t t h e e m a i l ?W h a t i s t h e i r r o l e w i t h i nt h e c o m p a n y ? What type of reviewis the companygoing to undertake? What is the obiectiveof the review? To: GerryKlein Subject:Internalreview
Dear colleagues, As you know,we are preparingto undertakea comprehensiveinterna|reviewoÍthe company'S your engineering organisatlonand facilities.A key area of this reviewwill be to assess how efficiently expertiseis being uti|ised.I wou|demphasisethat the aim oÍthis assessmentis not to questionyour professionalcompetence.On the contrary,I and the company'snew shareholdersrecognisethe high degreeoÍtechnica|expertisewithinthe organisation.our intentionis to work towardsoptimisingthis valuableresourceby identifyingthe demands on your time that are largelyunproductive(suchas administrative tasks)in orderto allowyour skillsto be used more productively. b The following extract is from a questionnaire used in the review which was sent to staff in the company's design department. Read the questionnaire and match each question (l-3) to points (a-c).
I I
Approximately what percentage oÍ your time do you spend on the types of task be|ow? For each question, the sum of va|ues given for A + B should equal íoo%. 'y" 1 A D o i n g t e c h n i c a l t a s k s t h a t u s e m y e n g i n e e r i n gs k i l l s e x t e n s i v e l y B
D o i n g m o d e r a t e l y t e c h n i c a l t a s k s t h a t a l e s s q u a l i f i e dc o l l e a g u e c o u l d d o - %
2
A B
D o i n g [ e c h n i c a l t a s k s t h a t a d d v a l u e [ e . 9 . d e s i g n r n g ,p r o b l e m - s o l v i n g-] D o i n g t a s k s t h a t d o n o t a d d v a l u e [ e . 9 . a d m i n i s t r a t i o n )- " / "
3
A B
D o i n g t a s k s t h a t a r e p u r e l yt e c h n i c a l - % D o i n q t a s k s t h a t r e l a t e t o t e c h n i c a l o r q a n i z a t i o na n d d e c i s i o n - m a k i n q- %
a The extent of technicalrole versus managementrole b The degree of commercialexploitationof technicalskills c The degree of applicationof expertiseand experience C )g,S Eleanor and Gerry two design engineers, are talking about the questionnaire. Listen and write approximate values, to the nearest l0o/o,for Gerry's answers to the questions. d
Complete the following sentences using the words or phrases in the box. Sometimes more than one answer is possible. tattparFq$í€ offthe top of myhead roughty somewhere in the regionof
nowherenear
prettymuch
I They asked for a baillparvk'qrt^"' for setting up the new system' 2 I'vegot the figures in my computer,but I couldn'ttell you finished,there'sjust the tidying up to do. 3 The work is the estimateat E2m over budget. 4 The actual cost of the stadiumwas 5 | think it'll take two weeks to completethe report. 6 T h e d e v e l o p m e nw t illcost $ 10m. 68
I
Unit 8 Monitoringand control
%
I
In pairs, ask and answerthe questionsfrom the questionnairein Exercise I I b usingthe phrases in Exercise I I d. Note down your partner's answers.
1,2 a
I
A-o/o
B-o/o
2
A-o/o
B-o/o
3
A-o/o
B-o/o
)a.g Rs part of the company'sinternatreview,an assessmentis being made of the hardwareand softwarethat make up the firm's ComputerAided Design (CAD)system.Dan, a design engineer,is talking to Beatrice,his manager, about the state of the system.Listen and mark the followingstatementsTiue CI)or False (F). I Most of the screensare too small. 2 Engineers spenda lot of timeworkingon screen. 3 Largenumbersof drawingsare printedat theiroffice. Find words and phrases in audioscript8.9 on page 93 to match the following definitions(l -5). I approximately / 2 muchmorethan/ (two thirds) 3 at least/ 4 most/ 5 almost zero / Complete the following replies to express the figures in approximate terms using the words in Exercises | 1d and l2b. Sometimes more than one answer is possible. A goü, (at |east 5 years) l How o|d is this equipment? five years o|d. percentage 2 What of the PCs need changing?all of them. (95o/o) 3 How many of the computersare up to spec? all of them. (1Oo/o) 4 How many of the staff use the CAD system? half of them. (55o/o) 5Howmuchwou|dthenewprinterscost?-$2'000.($3'l20) 6Howmuchdoesanadapter|ikethiscost?-($z; 7 How long would a full system take to install? 5 days. (4-6 days) (95o/o) 8 Can most of our clients read these files? Yes, of them.
13
You are setting up a small company of consulting engineers employing seven members of staff - five engineers and two assistants. You need to rent an office, equip it with a computer network with CAD system and admin software, and buy other basic office equipment. !n pairs, discuss some ballpark figures relating to the following questions. o o . .
What computerequipmentwill be requiredand how much will it cost to buy? What other items of furniture/equipment will be needed,and how much will this cost? How much floor space will be requiredin the open-planoffice? How long will it take to set up the office- installthe furnitureand equipment?
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Explaining testsandexperiments In pairs, discuss the following tests and experiments and their main advantages and disadvantages. computer models and simulations 2 reduced-scaletesting
I
2
3 full-scaletesting
a ln pairs, suggesthow the followingdevelopmenttools could be used for aerodynamictesting. o Computational o field testing FluidDynamics(CFD) o a windtunnelequippedwitha rollingroad )S.t Rn internationalteam of researchersare collaboratingon the design of an experimentalenergy-efficientvehicle.They are discussingthe tools availablefor developingthe vehicle'saerodynamicdesign. Listen to the conversationand answerthe followingquestions. I 2 3 4 5
Whatoptionsare availablefor windtunneltestingin termsof scale? Whyare rollingroadsusefulin windtunnelswhentestingvehicles? Whatissuewilldeterminewhetheror not a rollingroadis necessary? Whatpointis madeaboutthe reliability of CFD and windtunneldata? What problemis mentionedwith regardto outdoortesting?
)g.t tisten again and completethe followingextractsfrom the conversation using the words and phrases in the box. Theacidtest back-to-back testing in thefietd mock-up triatrun tried-and-testedvalidate vfttnt
70
1 2 3 4
... the testswouldobviouslgDe virtt^al , based on a computermodel. ... go into a wind tunnel,with a scale model,or a full-size ... tf's notjust about data gothering.Youalso have to the data. The onlg comes whengou trA out a full-scaleprototApein real outside,with conditions.We need to make sure that evergthingis a full-scale
5
... with changeable weather, it's not easA to do -
Unit 9 Theoryand practice
out
I
Match the words and phrases in Exercise 2c to the definitions (a-h). a
a 3D model simulatingshape and size,but without internalcomponents uaoclc-tep
b provento be reliablethroughrealuse/ trials c outdoors.in a realsituation not physical d describessomething simulatedby software, workse a crucialtrialto provewhetheror not something f trialsto comparetwodifferent in the sameconditions solutions, g provetheoretica|conceptsbytestingtheminrea|ityh a practicaltest of somethingnewor unknownto discoverits effectiveness Complete the aerodynamic design development plan of the energy-efficient vehicle using stages (a-e). a Test model in wind tunnel to validate data from scale tests b Carry out back-to-backtests in wind tunnel with mock-ups c Build full-sizeworking prototype d Select best design,based on data from wind tunnel tests e Narrow down design options to three,based on computerdata Aerodynamic design development plan
I Experiment usingCFD software
2
3 4 5 6 1 I 9 l0 il
3
Produce reduced-scalemock-upsof designsand test in wind tunnel
Buildfirstfull-scale mock-up Producetwo reviseddesignsto improveon full-scalemock-up Select best design, based on data from tests
Carryout fieldtestswithtrial runsoutside
You are membersof a technologicalresearchteam similar to the one in Exercise2b. You have been asked to design a test programmefor an experimentalsystemfor air-droppingcargo. Read the brief and, in pairs, discuss the types of test requiredand their sequence.
Design brief The system allows relativelyfragilecargo to be air-droppedfrom planes into remote locations on the ground.lt comprises a parachute,attached to a cylindricalcontainer two metres long with a diameter of 1.5 metres. The container is surrounded by a deformable protective structure. The aims of testing are to develop the designs of: a) the parachute b) the protective structure,in order to minimisethe impact to carto inside the container. The number of tests must be maximisedwithin a limited budget.As tests involving real drops from aircraft are costly, these must be kept to a minimum.
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Exchanging viewson predictionsandtheories
I 4
a tn pairs, answerthe followingquestions. I Whatkindsof cargois sometimesdroppedfrom aircraft,and why? 2 What are the advantages and disadvantages of air-drops?
Read the following predictions of how a container air-dropped with parachutes might behave while falling, and on hitting the ground. Complete the predictions by underlining the words you think are correct. I
The longer the containeris in the air, the more its horizontalspeed will decrease/increase. 2 Compared with a low-altitudedrop, the verticalspeed of a high-altitudedrop will be lower/higher. 3 In terms of damage to the container,a high vertical/horizontalimpact speed is potentiallyworse. 4 A very low-altitudedrop will most likelycause the containerto slide/roll along the ground. )g: Arnaud and Jenna, two engineers, are talking at the start of an airdrop research project. Which predictions in Exercise 4b do they agree on, and which do they disagree on? How do their ideas compare with yours?
5a
Rephrase the words in brackets to complete the following extracts from the conversation. lSo'-(intheory)'thehorizontalspeedwillkeepdecreasing... (assume)the drop altitude's verg low, ... 2 So, (sure) o low vertical speed is the critical factor. 3 ... (presume), if the groundspeed's quite high, there's a 4 Because, danger the container will roll ... (argue),rolling is the worst problem, ... 5 So, Rephrase the words in bold in the following sentences using the words in Exercise 5a. I I suppose there'llalwaysbe a certainamount of groundspeed. 2 lf we assume the containerwill roll, we'll need to protect it accordingly. 3 Accordlng to the hypothesis, groundspeedwill almost alwaysbe positive. 4 You could say that it's inevitablethe containerwill roll and bouncealong. 5 I'm convinced that high verticalspeed is less problematicthan high groundspeed.
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Unit 9 Theoryand practice
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c
In pairs, decide whether the following words and phrases are used to agree or disagree. can you think of other phrases for agreeing and disagreeing? Absolutely I'm not convinced I'm not so sure Not necessarily Of course True
d
Look at the diagram and, in pairs, discuss the following questions.
Dropaltitude Aircraftspeedandd'irection Windspeedanddirection speedof contajner Vert'icaI {{-
I
2 3
4 5
6
a
of container Airspeed of container Groundspeed
What is the differencebetweenairspeedand groundspeed?How do wind speed and wind directionresult in a differencebetweenan aircraft's airspeedand its groundsPeed? lf an aircraft'sgroundspeedand airspeedare the same, what must the wind speed be? In theory,an aircraftcan fly with a groundspeedof zero in certainextreme conditions.what would these conditionsbe, with regard to wind speed and the aircraft'sdirection relative to the wind? To minimisethe horizontalgroundspeedof an air-droppedcontaineron landing,what should the aircraft'sdirectionbe, relativeto the wind? lf severalair-dropsare carried out from the same altitudewith different wind speeds,how will higherwind speeds affectthe groundspeedof the containeron landing?
tn pairs, discuss which of the following options you think is preferable and why. I a low-leveldrop with low verticalspeed and high horizontalspeed 2 a high-leveldrop with high verticalspeed and low horizontalspeed In pairs, discuss how the design of the container used for dropping cargo would be different for each of the two options in Exercise 6a. For each situation, consider how the container could be built to cushion the type of impact. In particular, think about the shape of the container and the protective structure around it.
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-
Comparingresultswith expectations 7a
ln pairs, discuss the difference between expectations and results. Cive an example relating to research and development (R&D) in engineering. Manfred Haug, an aeronautical engineer, is describing his early rocket experiments. Read the description and explain what is meant by the expressions in bold. Relging on trial and error isn't olwags the best wag to improve technologg, but I found it was an effective waA to develop roclsets. Especiallg as rocket science was unfamiliar territorg for me. I was on a steep learning cule, hence the numerous explosions. Read more of the description. What kinds of rocket did they build and how do you think they worked? I should sag that this had nothing to do with NASA, and happened a long wag from Cape Canaveral. lt was just me and a few friends on a windswept football field near Homburg. But the plastic bottle water rockets we built and launched went through an impressive R&.D progromme, bearing in mind we were onlg 12 gears old!
!l 8a
)g.S tisten to an interview with Manfred about building and launching water rockets and answer the following questions. I How full were the bottles? 2 What coincidencewas helpful? 3 How powerful was the rocket? 4 What problem occurred? Read the following extracts from the interview. What is meant by the words in bold?
lt
1 ... we expected it would shoot up reasonablg fast . 2 ... we didn't anticipate just how powerful it would be. 3 lt totallg exceeded our expectations.
9a
In pairs, discuss two or three solutions to the problem experienced with the rocket, based on basic materials and simple assembly techniques. For each potential solution, explain how you would expect the rocket to perform and why, describing potential problems for each solution. )g.q Vanfred goes on to describe how he and his friends solved the problem. Listen to the description and summarise the solution, explaining why it was effective. How does the solution compare with your ideas in Exercise 9a? )g.q Usten again and complete the following phrases from the description. I (as expected) lt didn't go exactlg 2 (extremelywell) lt worked
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Unit 9 Theoryand practice
t0a
tn pairs, discuss possibleways of makingthe water rocket more powerfulto allow it to attain higher altitudes.The basis of the design should be the sameandyoumayon|yusebasicmaterials.Foreachsolution,explainthe followingpoints. o Why you wouldexpectthe rocketto be moreeffective . Any potentialProblems the )g.S tisten to Manfred describinghow the rocket was developedand their and made improvements the on notes Make tests. results of further consequences.How do the solutionscomparewith your ideas from Exercise lOa? Read the followingphrasesthat Manfred uses.complete the definitionsby underliningthe correct words. : what happenedin theory/prcllCe 1 as it turnedout : what happenedin theory/practice hoppened actuallg what 2 : it was less/morethan we thought pressure the underestimated we 3 : it was less/more than we thought 4 we overestimatedthe strength : they'readequate/inadequate 5 plastic bottlesore hardlgup to theiob : it was a theoretical/practicallesson 6 I learnedthe hard wag. ln pairs, discussthe followingquestions. of buildingthingswhenyouwereyounger o Did you haveanyexperiences or whichdidn'tturnout as you'dexpected?what did you underestlmate What lessonsdid you learnthe hard way? overestimate? in helping weremostbeneficial whatexperiences o when youwereyounger, you learn? principles did youto improveyourtechnicalskills?what technical
1t
Amateur rocket scientistshave producedwater rockets capable of reaching altitudes of severalhundredmetres in competitions.In pairs, think of initial ideas for a suitable designwhich complieswith the followingcompetitionrules'
Water Rocket GomPetition {f Rockets must be assembled entirelyfrom consumer Products Purchasedfrom supermarkets or DIY stores. For safety reasons, no glass or metalliccomponents are permitted. {f Flocketswill be pressurised, and anchored duringpressurisationusing a compressor and launch pad providedby the organisers Jf Release of the rocket will be triggered by competitors, from a distance, by rope' at the moment deemed appropriate by the competitor,based on a reading on the pressure gauge of the comPnessor.
Unit 9 Theoryand Practice
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Discussingcausesand effects In pairs, discuss the difference between cause and effect in each of the following situations. 1 a vehicletyre overheating 2 a n e l e c t r i c acl i r c u i to v e r l o a d i n g 3 a s h i p ' sh u l l c o r r o d i n g
t3a
Read the title of the article in Exercise I 3b and explain what you think it means.
b
Read the article and answer the following questions. I What are chickencannonsdesignedto do? 2 Why was a chickencannon used for a train test? 3 What were the effectsof the test?
CHIGKEI{ CAlIl{ol{GOOFMAKESTECHEGGHEADS IOOKLIKETURKEYS jet \f,/nen new aircraft are developed, Y Y engines and cockpit windshields are tested to simulate bird strikes (mid-air collisions with birds), which can result in damage. The tests are carried out using special compressed-air cannons that fire dead chickens. On one occasion such a gun was lent, by an aeronautical company, to some engineers developing a new train. Bird strikes were a potential danger, owing to the train's high speed. Having received instructions in how to use the cannon, the train designers bought an oven-ready chicken from a local supermarket, and subsequently fired it at their prototype.
l, |Í
lt
The effects were devastating. As a result of the impact, a hole was smashed, not just through the windshield, but also through the back of the driver's compartment. It was hard to believe a chicken had caused so much destruction. Consequently,the engineers contacted their aeronautical colleagues to enquire if the problem might be due to an issue with the gun, some sort of fault that could have caused it to exceed its normal firing power. No malfunctions were found. However, it was later discovered that the unexpected damage had occurred because of a temperature issue.
The text in Exercise I 3b is an urban legend (or urban myth) - a commonly told story that is said to be true, but which is not. Can you guess what temperature issue caused the unexpected effects?
d
Complete the following sentences using the words and phrases in the box. becauseof (x2) caused consequentlydueto owingto rtsuttin resultof I Bird strikes 62n vesqlt i\ damage to aircraft. 2BirdstrikesWereapotentia|prob|emforthetrain,-l Iits speed. 5 During the test, the train was severelydamaged as a the impact. 4 The damage occurred a problem relatingto temperature. 5Theimpactofthechicken-ittoenterthetrain. 6Theengineersthoughtthegunwasfau|ty,so-theyca||edtheir colleagues.
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Unit 9 Theoryand practice
e
Read the following engineering urban legends and complete the descriptions of causes and effects using the correct form of the words and phrases in Exercise I 3d. Sometimes more than one word or phrase is possible. 1 Apparently,the biggestchallengein space explorationwas developinga pen for astronautsto use in orbit as ordinary ballpointpens don't work in space, becatuse oP / Arl.elo / ow\t\glo the fact that there's no gravity. So this problem,there were teams of researchersworkingfor years,trying to find a solution.Eventually,someone came up with the idea o f u s i n ga p e n c i l . 2 When they designedthe foundationsof the library on the universitycampus, they forgot to allow for the weightof the books on the shelves,which the buildingto start sinking.So , half of the floors have had to be left empty,without books, to keep the weight down. 3 Did you hear about that Olympic-sizedswimmingpool that was built? They got the lengthwrong, the tiles.They forgot to take into accountthe thickness,which the pool measuringa few mi||imetrestooShort.So-,itcan'tbeusedforswimming comoetitions.
14a
One popular topic for urban legends is the suggestion that the moon landings didn't really take place and were filmed on Earth. ln pairs, discuss the following questions. . o o .
In photos taken of astronautson the moon, why are no stars visible in the sky? In film footage,why is the flag planted on the surfaceof the moon seen m o v i n gs l i g h t l y ? Why do photos of astronauts'footprintsappear to be on a wet surfaceand not in dry dust? W h y i s n o b l a s t c r a t e rc a u s e db y e n g i n et h r u s td u r i n gt h e l a n d i n gv i s i b l e b e l o wt h e m o d u l e ?
)g.S Caroline and Renato, two colleagues at an engineering firm, are talking about the moon landings during a coffee break. Listen to the conversation and compare what they say with your ideas from Exercise 14a. C
ln pairs, discuss any urban legends you have heard relating to engineering and technology. Use the following ideas to help you. o . o o
unbelievabld e e s i g nf a u l t s bizarre incidents involvingcars r u m o u r sa b o u t a m a z i n g experimentaltechnology b a d w o r k m a n s h i pb y =
plumbers builders, and electricians
'G';;-.=
jf-=*"::H Unit 9 Theoryand practice .i.
UNIT 10
E
performance Discussing and suitabitity Describingphysicalforces Discussingrelativeperformance Describing capabilities and limitations
a o a
Discussingperformance and suítability
I 1a
ln pairs, answer the following questions about wind turbines. 1 W h a t f u n c t i o nd o w i n d t u r b i n e sp e r f o r m ? 2 W h a t a r e t h e m a i n a d v a n t a g e sa n d d i s a d v a n t a g eos f w i n d t u r b i n e s ? 3 What types of locationare most suitablefor wind farms?
b
ln pairs, discuss the functions and technical characteristics of the following wind turbine components. btades
2a
tower
qenerator
)tO.t Vit e, Loreta and Hanif, engineers at a wind turbine constructor,are discussing performance and suitability issues relating to offshore wind turbines. Listen to the conversation and answer the following questions. I W h i c hw l n d t u r b i n ec o m p o n e n td o t h e e n g i n e e r sd i s c u s s ? 2 W h a t i s t h e b i g p r o b l e mw i t h o f f s h o r ei n s t a l l a t i o n s ? 3 W h i c h t w o t y p e so f c o n s t r u c t i o nm a t e r i a la r e b e i n gc o m p a r e d ? 4 Why are coastaldefencesmentioned? 5 W h a t p o i n t d o e s H a n i fm a k e a b o u t r e g u l a rm a i n t e n a n c e ? 6 What comparisonneeds to be made with regard to lifespan?
b
Match the words (l -6) from the discussion to the definitions (a-0. 1 2
C
a
3 4
appropriate/suitabte consistent/retiable cost-effective/economical effective
b c d
the right sotutionfor a particularsituation good enoughfor the intendedfunction performsa functionwe[. worksquicktyand well
5 6
efficient sufficient/adequate
e f
makesthe most of resources,isn't wasteful doesn'tbreakdown,atwaysperformsin the sameway
Make the following words negative by adding the prefixes in- or un-. l
adequate
i\4áeqr^at!e
2 appropriate 3 consistent 4 economical 5 effective 78
U n i t 1 0 P u s h i n gt h e b o u n d a r i e s
6 7 8 9
eflicient reliable sufficient suitable
d 3a
)tO.t tisten again. What issues do Mike, Loreta and Hanif agree and disagreeon? The followinginformationis from the web site of Sigma Power,a firm that advises corporate and governmentclients on wind enerS/ proiects. Completethe text usingthe words in Exercise2c.
E E E E
IE
I
The fact that wind turbinesconsumeno fuel and waste very littleenergyis clearlya fundamental are they? Key figures advantage.But just fiev7 e$$crerrt Clearly,wind turbinesneed to be locatedon relativelywindy sitesin orderto function.Froma ? what kindsoí geographical Iocationarethe mostmeteorologicaI standpoint, Turbinesare generallyplacedat the tops of tall towers,where wind speedsare highel thus . What otherpositioningfactors influenceperformance? makingthem more Windturbinesrare|yÍunctioncontinuous|y,duetothefactthatwindspeedsare-' is the impactof variable weather conditionson powergeneratingcapacity? How significant Transmittingelectricityover long distancesis inherently , due to power lossfrom powerlines.Findout moreaboutthe advantagesof generating overheador underground power locally. for it to be reliedupon The generatingcapacityof wind turbinesis generally provide? generating realistically percentage wind turbines capacity can of total What 100%. Someear|ywindturbinesWere-,sufferin9breakdownscausedbyinaxia| stressesstemmingfrom higherwind loadson the upper blade.Howevel this problemhas been overcomeon modernunits.Learnmoreaboutthe technica|evolution of wind turbínes
at
{
You are engineersat Sigma Power.The marketingmanagerhas asked you to provide some technicalanswersfor the frequentlyasked questions sectionof the company'swebsite.The FAO section is aimed primarily at potential clientswho are thinkingof installingwind turbines at their sites - factories,office complexes,hospitals,and universitycampuses.ln pairs, discuss the followingquestionsand write the answersfor the website using the informationin the fact file and your own knowledge.
of havinga windturbineat my site? What'sthe big advantage are How dependable arewindturbinesas a sourceof power,giventhatweatherconditions changeable? relative to naturalfactorssuchas What kindsof sitearemostsuitablefor windturbines, hills,the coast,and heightabovesealevel? What'sthe mostappropriatelocationfor my wind turbine,relativeto localfeatureson the site,suchas treesand buildings?
-''!lrF
Unit 10 Pushingthe boundaries
79
I
Describingphysicalforces
4
a Read the foilowingarticre.what is a sorar tower and how does it use the forces of expansionand pressure?
j9L\jJ
7btu.,
cruue b rcrrrcltc energy?
.Í{)
Iy!;ls
Theneedto developrenewable energyis widelyseenas a futuristic technological challenge. Inreality, someof the mosteffectivewaysof harnessinghorsepowerfromnature are basedon conceptsthat haveexistedfor donkey'syears. Thewindturbineis an obviousexample.Another- less wellknown,butconceivedalmosta centuryago- is the solartoweror solarchimney. And if the Australian company EnviroMission completesan ambitioussolartowerproject in the NewSouthWalesdesert,the technology could capturenotjustthe sun! raysbutthe public'simagination worldwide. Thefirmis planningto constructa towera colossalonekilometrehigh.lf built,it witlbe the world's talleststructureby a hugemargin.
Howit works
A largeglassenclosureis built,witha chimneyat its centre. Thesun heatsthe enclosure, causingexpansionofthe air inside.At the top of the chimney, the lowertemperature and lowerpressuredueto the higheraltitudecreatea pressure differentialknownas stackeffect.This causesair to flow is generatedby turbinesat the up the chimney. Electricity whicharedrivenby the flowof air. bottomof the chimney, Thebiggerthe areaof glassandthetallerthe chimney, the greaterthe airflowandthe higherthe generating capacity.
b c
What physical forces would act on a solar tower I km high? )to.z su, a structurar engineer specialising rn the design of very tail structures, is giving a talk to a group of engineering students. Listen to the talk. Which of the forces in the box doesn't she mention? !9n!ing centrifugalforce compressioncontraction expansion friction pÍessureshear tension torsion/torque
'(D)'#
Label the diagrams using the forces in Exercise 4c.
lEr'.-J--l cor4PYessro\
;-EI 6tl8
80
,[É
Unit 10 Pushingthe boundaries
Tira'Tq ---T44--
'o11l
)tO.Z Comptete the following sentences from the talk using the forces in Exercise 4c. Listen again and check your answers. 1 So thot downward force meons the structure is in cou^pyessio\. especiallU neor the bottom. 2 ... a horizontal load, exerted bg air -against one side of the structure. 3 Becouse the structure is fixed at ground level, and free ot the top, that generotes forces. 4 ... when elements bend, gou have opposing forces: at one side, at the other. 5 ... the wind effectivelg tries to slide the structure along the ground, and the foundations below the qround resist that. The result of that /s force ... 6 . .. the foundotions need to relu on with the qround to resist the pull-out force, ... 1 The action of the wind can also generate . You get a twisting force ... 8 When concrete absorbs heot from the sun, Aou get ; as soon as the sun goes in, there's You and your partner specialise in designing structures for electrical transmission grids. You are currently working on a cable support concept for power lines near wind farms exposed to severe weather. You have come up with the following design. !n pairs, hold a short meeting to evaluate your design concept. Explain the forces acting on the structure.
Severe weather cable support concept
beam
wind direction1 ::
_____
column11
z
winddirection2
pivoting insulators
\ .\____
_
column2-v
--R ----\ cables
leg 3
leg 11
t, leg
v.
lpg 4
\
\
J
concnete foundations U n i t 1 0 P u s h i n gt h e b o u n d a r i e s
81
Discussingrelativeperformance
I 5a
In pairs, discuss the advantages and disadvantages of air and highspeed rail travel. Focus on trips of between 500km and I ,500km, the journey length over which planes and trains often compete for the same passengers. Read the extract from an article about transport in a popular science and technology magazine and answer the following questions. I What factorsshould be consideredin the comparativeanalysisdescribed? 2 What is the purpose of the comparativeanalysis? 3 What suggestionis made about Europe? convenience, efficiency, and Qpeed, four factors Jenüronmental-friendliness: with which to assess the relative effectiveness of different long-distance, mass-transport solutions for passengers. Technology: the key criterion in determining what transport solutions are available. And distance: the main consideration when categorising routes. Blend
these variables together in varying quantities, and you have a model for calculating the optimum way of moving people. On a European scale, whichever way you mix the various criteria, the most advantageous way oÍ getting people around the heart of the continent seems to be on high-speed, electric trains.
Find words in the text in Exercise 5b to match to the following definitions. Which one of the words has a plural form? 1 standard by which you judge something
6a
2
fact or situationwhich influencesthe result of something
3
n u m b e r ,a m o u n to r s i t u a t i o nw h i c hc a n c h a n g e
What do you know about France's high-speed train, the TGV? What is its normal operating speed? What is the approximate length of the train? Read the facts about the world speed record set by the TGV. Compare the world record journey with a normal TGV journey, using your answers in Exercise 5a.
World Speed Recordfor an In-Service PassengerTrain Date loi"ti"n Train Record
82 I
April 3,2007 Fiance:Paristo Strasbourgline on slightlYmodifredtrack StándárdTGV With fewer coaches 574.8km/h
Unit 10 Pushingthe boundaries
C )fO.l Andrej, a consulting engineer specialising in rail technology,is talking about the TGV world speed record. Listen to the talk and answer the following questions. I Overall, how heavilymodifiedwas the train? 2 How long was the record-breakingTCV? 3 Why was some of the bodyworkmodified? 4 Why was the diameterof the wheelschanged? d )fo.l Listen again and complete the following table about the modified TGV using the figures in the box. + 680/o + 79olo - t5olo
- 509o
Technical criteria
+ 80o/o
Modified TGV: % difference from standard model
Maximumspeed Trainlength (with coaches) Aerodynamicdrag Diameterof wheels Motorpoweroutput g
Complete the following sentences from the talk by underlining the correct words. 1
2 3 4 5 6 -I
f
The record speed exceeded the standard
operating speed bg a ting/hlltp
margin. The train was modified to a ceftain/considerable extent ... ... the modified train was significantlg/slightlg shorter, ... ... changes were made to the bodgworlt, to moke it slightlg/much more aerodgnamic... The wheels on the modified train were marginallg/substantiallg bigger ... ... the power of the electric motors wos marginallg/substantiallg higher thon the standard units ... ... standard high-speed trains con be made to go foster bg a slight/ considerable amount.
Rewrite the following sentences to describe the modifications that were made to the TGV for the record attempt. Use the phrases in Exercise 6e to replace the words in bold. The supply voltagein the catenarycables had to be increasedfrom 25,000 to 3l.OOOvolts. 2 To limit oscillation,the tension of the catenarycables had to be increasedby 60o/o. 3 On some curves,the camber of the track had to be increasedby a few centimetres. 4 The 574.8km/h record beat the previousrecord,set in 1990, by 59.5 km/h. 5 ln perfectconditionsthe TGV could probably have gone faster by 5 to l0 km/h. I
7
In pairs, choose a product or type of technology you know well and compare its performance and quality with an earlier model, describing the extent of the differences.
Unit 10 Pushingthe boundaries
83
I
Describingcapabilitiesand limitations 8a
Look at the photos and read the extracts Írom The Storg of John Paul Stapp, by Nick T. Spark, and answer the following questions. When and where do you think it took place? What do you think the aim of the test was? What do you think John Stapp's professionwas? What equipmentdo you think was used? W h a t d o y o u t h i n k h a p p e n e di n t h e e x p e r i m e n t ?
I 2 3 4 5
the sled'smovie cameras'and With five secondsto go Stappactivated rocketsdetonatedwith a nine p;;;;;;J to. tt. ,t ott' ioiii wi"a't and blastingStappdown the track' terrificroar.sendingot'iitutt' of fire ' ' ' sonic wind hit the water brake. The rear of the sred tore away. The fronr continued' hardry slowing at alr unt' it hJ; ;. second warer brake. Then, spray exploded from the back oÍSonic win|i.itstopped like it had hit a concrete wall. )tO.l Listen to an extract from a documentary about the experiment and check your answers to Exercise 8a. Complete the following data on the Sonrc Wind test using the figures in the box. r.2 3 20 46 101s I Max soeed:km/h 2 Accelerationfrom 0 to max speed: 3 Acceleration force: Cs 4 Decelerationtime: seconds 5 Decelerationforce: Cs
seconds
) tO.Stisten to the next part of the documentary and check your answers to Exercise 8c. Complete the following groups of synonyms using the words in the box. ableto capableof copewith exceed incapabteof intendedfor srliette.d{o surpass unableto withstand 1 2 3 4 5 6
84 I
exposed to (a force) / s'^biecte/ to resist (a forceJ| |go beyond (a limit)I Isuitablefor (a use)I c a nI - l c a n ' tl - l -
Unit 10 Pushingthe boundaries
I
Complete the following sentences about Sonrc Wind using the correct form of the words in Exercise8e. I The boltsfixingthe camerato the sled had to coPe with highshearforces. generatingenormousthrust. 2 The sled'srocketswerepools stop the sled rapidly. 3 The at the end of the trackwerehighlevelsof friction. 4 The skidson the sled had to severaltonnesof air pressure. 5 At full speed,John Stappwasand resistthe shockof deceleration, 6 The rear of the sled wasbroke off. survivingforcesof 17 Gs and above. 7 Doctorsthoughtpeoplewerethe I 7 G limitby a hugemargin. 8 JohnStapp-
9a
You are a consultant engineerand your firm have received an email from an entrepreneurwith an ambitiousplan. Read the followingemail extractand note the key information. !n pairs, discussthe key informationin Exercise9a and considerthe followingpoints. o the levelof G force o a safelengthfor the track o the feasibility of usingwheelg o the suitability of the braking systemssuggested )to.o Jasmine and Andrew, consultingengineers,are discussingthe issues in Exercise9b. Listen and compare what they say with your ideas from Exercise 9b. !n pairs, discussthe points raised in their conversationand make notes summarisingyour thoughtsin preparationfor a meetingwith the entrepreneur. Prepare a short presentation for the entrepreneurusingyour notes from Exercise9d. Student A, you are the consultant engineer.Give the presentation. Student B, you are the entrepreneur.Listen and ask questionsabout specificdetails. Swap roles and practise again.
I
To;JasmineMurray Subiect: The proposal is to build a rocket sled ride on a desert site in Western Australia.The ridewillbe aimedat wealthytourists,and willallow themto experiencesupersonicspeeds.We envisagecarryingtwo passengersat a time,seatedbehindthe pilot.The idea is inspired which I'msure you'refamiliarwith. by the Sonic Wind experiments, However,it goes withoutsaying that safetywill be the numberone priority,which means that e)dremesof accelerationand deceleration must be avoided.For instance,a waterbrake,likethe one used in the Sonic Wind tests,is clearlyout of the question. The site is largeenoughto accommodatea track up to 16 km long,thoughI reckon1Okm would be adequate.Accordingto my roughca|cu|ations,that wou|dbe sufÍicientto al|owprogressive accelerationup to and throughthe sound barrierto about 350 m/s, to a standstillwithoutexceeding2 G and progressivedeceleration (20 m/s,),while still leavingthreeto four kilometresof track as a safety margin.However,I'm not an engineer,so would appreciate your professional opinionon that. I assumethe most suitab|evehic|e ln termsoÍbasic techno|ogy, would be a rail-mounted sled,withsteelskids that gripthe track, aboveand belowthe rails,to preventderailing,and avoidproblems withaerodynamiclift.I assumewheelswouldn'tbe feasiblegiventhe speeds involved,thoughI'm not 100%sure aboutthat,Perhapsyou can advise.Propulsionwould be providedby a rocketor aircraft.jet. I alreadyhave a consultantsourcinga suitableengine, however,so thatangleis beinglookedinto. As far as your inputis concerned,the mainareawhereI need your expertiseis on the brakingsystem.As I said,violentbrakingis out of the question.As I see it,suitablygentleoptionsincludesystemsthat app|yfrictionto the rai|s,aerodynamicÍ|aps,parachutes,or reversed enginethrust.But, again,I'm not an engineer,so I look forwardto discussingyourthoughtson these issues.
-":ar
Unit 10 Pushingthe boundaries
85
This glossarycontains usefultechnicalwords from the texB and audioscriptswhich are not coveredspecificallyin the exercises.
bearing
mechanismcontainingballs or rollers placed around a componentwhich spins,e.g. a shaft,to reduce friction
belt (drivebelt)
closed band placed around two or more wheels (pulleys),allowingone wheel to drive the other(s)
cable
rope made of many wires,usually metal
component
individualpart of an assembly/mechanism
electromagnetic
generatedmagneticfie|d haíuses an e|ectrica||y
foundation
base supportinga buildingor structure,usuallymade of concrete
gears
wheelswith cogs (teeth)which mesh togetherto transferdrive from one wheel to the other wherethe wheels are side by side
inertia
the resistanceof an obtectto accelerationor decelerationdue to its mass
lubricant
|iquidor viscous so|id (e.g.oil) used to reducefriction betweenmovingparts whose surÍacesare touching
(electric)motor
device which transformselectricalenergyinto rotary motion
pile
foundationcomprisinga vertical columnof concretein the ground
propeller
device with spinning blades used to push boats or aircraftthroughwater or air
reinforcement
networksoffibres or bars placed inside a materialto strengthenit, e.g.steel reinforcementin concrete
remote control
siystemused to control a device or vehiclefrom a distance,usuallyvia a wirelessconnection
sheave
alternativeterm for pulley (seebert above)
solar power
energyfrom sunlightconvertedinto electricalenergy
strength-to-weight ratio
toughnessof a materia|(abi|ityto resist breaking)re|ativeto its density (density = masívo|ume)
structuralengineer
engineerspecialisingin the design of structures,e.g. bridges
wind load
force exerted on a structureby the wind
wireless
signal transmissionwithout a physicalconnectionby wire, e.g. by radio wavesor infraredwaves
aggrega[e
solid particles or lumps of material used in a mixture,e.g. sand and gravelin concrete
automotive
related to vehicle design and manulacturing
blade
cutting device,often metal with a sharp or toothed edge
cement
lime-basedpowder mixed with water to make concrete
chassis
base of a vehicleto which all main componentsare fixed
composite(material) combined materials;consistsof a bulk material (calleda matrix) reinforcedwith fibres or bars, e.g.glassreinforcedplastic [plasticmatrix with glass fibres) material that conducB (carrieslelectricityor heat - in engineering,usuallyrefiersto an electrical conductor
conductor electrolysis
passing an electricalcurrent througha liquid or solid in order to separatechemicalcompounds
exhaust galvanized
systemfor evacuatingsmoke or gases,e.g.from an engine coated with zinc - us€d to protect steel from corrosion (rustingl
insulation
protectivelayer to preventor reduceconductionof heat or electricity
ironmongery
collectiveterm for small metal items commonlyused in buildings,e.g.door handles,hinges,screws,nails
kinetic energy
energy in the form of movement,e.g.a spinningwheel
melt down
changea solid substanceinto a liquid by heating it
membrane
thin layer of material,often acting as a barrier,e.g.to preventwater passing
puncture
hole causinga leak of air or liquid, e.g. in a tyre
rust
common name br iron oxide - producedwhen iron corrodesas a result of exposureto air and water
scrap
used/recoveredmaterial intendedfor recycling;often refersto metal
108
Glossaryof technicatterms
acetylene
gas commonlymixedwithoxygenin welding(oxy-acetylene)
ballast
densematerialusedto add weight,e.g.as a counter-balance or to resistlift
cable tie
plastic strap used to fix severalcables togetherside by side, or to fix cables to a supportingstructure
casting
pouringmoltenmaterialinto a mould
eartn
electricalconnectionbetweena circuitand the ground
live
in a mainselectricalcircuit,the wirethroughwhichcurrentflowsinto an appliance- also meansa circuit is energised(currentis flowing)
machining
collectiveterm for processesinvolvingcutting,drilling,etc.
millingmachine
machineWithcuttingwhee|susedto cut awaythe surfaceof metá|in thin |ayers
neutral
in a mainselectricalcircuit,the wirethoughwhichcurrentflowsout of an appliance
black bolt
in construction, an ordinarybolt
cabletray
long metalplateon whichcablesare laid - designedto supportlargenumbersofcables
column
verticalsupport in a structure
constructionjoint
ioint beMeen two sectionsof concretethat were poured at differenttimes (whereconcretestructuresare poured in severalstages)
duct
large section pipe,with a circularor square profile,for carryingair; or a protectivecover for cables or hoses
fabrication
making/assembling, often used to describe metalwork
fixings
collectiveterm ficrbolts, screws,rivets and clips
high strengthfriction erip [HSFG)bolt
bolt which holds plates togetherby friction (grippingthem tightly together)rather than by shear force
M&E
abbreviationfor mechonicaland electrical - in construction,refersto electricalinstallations,water pipes,air-conditioning, etc.
pour lconcrete)
Dlace/castconcrete
slab
large flat area of concrete,for a floor or roof
'fu$iffiÉÉ clearance
distancebetweencomponentsdesignedto fit togetherclosely
clutch
friction mechanismallowingengine motion to be transferredto wheels progressively
coolant
liquid in a cooling system
orag
resistanceto movementthrougha gas or liquid,e.g.whena planemovesthroughthe air
electricalcontact
point where two electricalconductorsare connected
engine
often refersto an internal combustionengine- i.e. one which burns petrol or diesel
fan
spinningdevicewith bladesusedto generatea flowof air
filter
materialwith small holeslocatedin a flowof gas or liquid;usedto blocksolid particles,e.g.to prevent themfrom damaginga sensitivemechanismsuchas a pump
f|aps
moveab|epane|son aircraftWingsWhichincrease|iftto assist |ow.speedf|ight'e.g.during take.ofíand landing
fly-by-wire
aircraftcontrolswhich operate moveabledevices(e.9.flaps)electronically,rather than mechanically
fuel iniection
systemfor injectingfuel vapour into the piston cylinderof an engine
temperaturegau€ e
deviceWhichshowsa temperaturereading
gearbox
gearsto be movedto casecontáiningshaftswithgears'usual|ywith a gearshiftmechanism,a||owing changebetweendifferentgear ratios
hydraulics
high-pressure oil circuitsusedto pushpistonscalledhydraulicrams
isolate
separatean electricalcomponentor part of a circuitfrom the rest of the circuit- e.g.by openinga switch- to preventelectricityfrom flowingthroughit
landinggear
wheelsof an aircraft
looseconnection
electricalconnectionthat is not fullytight,oftencausingthe circuitto be broken,preventingcurrent from flowing
misfire
whenan engineis not runningsmoothlydue to a fuelor ignitionproblem
non-serviceable (part)
part that cannotbe repairedby maintenance technicians, only by the manufacturer
prston
mechanismwhich transferslinear motion (backwardand forwardmovement)to rotary motion (turning movement), usuallypushedby expandinggas
Glossaryof technicalterms
109
radiator
heat-exchange devicethat dissipatesheat intothe air,usuallyfrom a hot liquid(e.9.coolant)that is pumpedthroughit
spoilers
moveablepanelson aircraftwingswhichincreasedrag and reducelifti usedto slowaircraftwhen descendingand on landing
starter motor
e|ectricmotor in an engineusedto turn the en€ i ne in orderto start it running
suspension
moveableconnectionbetweena vehicle'schassisand its wheels,consistingofspringsand dampers
tanK
containerfor storingllquid
throttle
acceleratorcontrolon an engine
turbine
transformsa flowof fluid (liquidor gas)into rotarymovement,e.g.a windturbine
VAIVC
mechanismfor opening/closing/restricting the flowof gas or liquidalonga pipe
Unit6 beam
long,narrowhorlzontalcomponentin a structure
core drill
hole-sawfor drillingthroughthick materials
cra ne
machinefor liftingheavyobjects,able to reachsignificantheightsand distances;includesmobilecranes (whichwheel),towercranes(whichare supportedby a fixed tower)and gantrycranes(whichrun along beams)
dynamic
relatedto movement,e.g.a dynamicload [: a load generatedby a movingobject)
C-force
f o r c e o fa c c e l e r a t i o n o r d e c e l e r a t iIo C n i:s e q u i v a l e n t t o t h e f o r c e oafc c e l e r a t i o n e x e r t e d b y g r a v i t y
jib
moveablearm of a crane
lifting eye
ringfixed to a heavyobjectallowinga hook (e.9.of a crane)to be attachedto enablelifting
low-loader
truckwitha low flat trailer,usedfor transportinglargeheavyvehicles,especiallyconstructionplant
slings
flat strapswhichcan be attachedto cranehooksand placedunderobjectsin orderto lift them
thrust
pushin€ force,e.g.generatedby expandinggasesexitinga rocket
Unit 7 airinlet
pointwhereair entersa deviceor process- the oppositeis air outlet
arc
electricalcurrenttravelllnga shortdistancethroughthe air to flowbetweentwo conductors
Dlower
pump-likemechanismwhichgeneratesairflow
circuitbreaker
electricaldevicewhichinstantlybreaksa circuit(switches off the powersupply)as a safetymeasureif a variationin currentis detected
extinguisher (fireextinguisher)
deviceusedfor puttingout fires;usuallya metalcontainerwitha hoseor nozzlecontainingwater,CO,, powderor foam
guardrail
safetyrail designedto preventpeoplefallingfrom highplaces
metalcontainerwhichcontainscompressedgas,oftenin liquefiedform handrail
(asguardrail,above)
load-bearing
describesa part of a structureor assemblythat is designedto resisUtransmit force
moisture-sensitlve can be damagedby water off-cuts
wastepiecesleftoveraftercutting
shot-blasting
firingsmall metalballs propelledby compressedair as an abrasivecleaningprocess
stlo
largecontainerfor storingbuIk€ r anu|ar materialssuchas grain
strain
chan€ e in size/shape of a component(e'g'stretching) due to force
switchboard
controlpanelcontainingseveralswitchesfor all the individualcircuitsof an electricalinstallation
switchgear
collectiveterm for switchingequipment
transformer
electricaldevicefor modifyingcurrentand voltage- a step-uptransformerincreasesvoltageand reduces current,a step-downtransformerdecreasesvoltageand increasescurrent
Unit 8 AC
AlternatingCurrent
automation
automaticcontrolof a system,deviceor process ComputerAided Design- computersoftwarefor producingengineering drawings
CAD conv€ y or beIt
processesand movingbelt whichtransportsobjectshorizontallyi oftenused in manufacturing warenouses
downstream
furtherdownthe directionofflow (e.g.in a river);used in engineering to describeindustrlalprocesses and the flowof liquid/airin pipe/ductnetworks(opposite= upstream)
electricutility
companywhichgenerateselectricityat powerstations
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Glossaryof technicaIterms
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electricalcharge
stored electricity(potentialelectricalenergy)
exothermicreaction
chemicalreactionwhich producesheat (opposite - endothermicreaction,which absorbs heat)
f low
movementof a substance,usuallya liquidor gas (e.9.alonga pipe)
gizmo
slang term for a technicaldevice,usuallyelectronic- suggeststhe device is complex
hydroelectricpower
electricitygeneratedusingwater pressure(hydrostaticpressure)
mainselectricity manual
domesticelectricitysupplysystem controlledby a person - the opposite is automatlc
refrigeration
processof coolingto temperaturesbelow atmospherictemperature
reservoir
power man-madelakefor storingwater,usuallyfor drinkingwateror hydroelectric
standby (on standby) when a device is ready to operate immediately,e.g.a TV that is ready to switchon when it receivesa remotecontrol signal vessel
closed tank which can hold a pressuregreater than the atmosphericpressureoutside it
aerodynamics
study of airflow e.g.over movingvehiclesand aircraft
aeronautical
relatedto the design and constructionof aircraft
centre of gravity
theoreticalpoint on the cross-sectionof an object from which the obiects mass is transmittedvertically downwardsdue to gravity
compressor
device for pressurisinggas (usuallyair) inside a vesselor networkof pipes/hoses
data gatherin€
collectingand recordingthe results of tests for later analysis
deformable
can changeshape
deploy
release/ejecvopen, e.g.when skydiverspull the cord oftheir parachute,the parachuteis deployed
destructible
can be / is designedto be broken/destroyed Do lt Yourselfstore - hardware/ home improvementsstore selling building materials and tools to consumers
DIY store
turbulence
devicewhich showsa pressurereading,e.g. in bar or psi [poundsper square inch) disturbed airflow- i.e. air not flowingsmoothlyaround an obiect
vacuum
volumecontainingno gas, e.g.space
windshield
glass at front of a vehicleor aircraftwhich the driver or pilot looks through,also called a windscreenin BritishEnglish
pressuregauge
;Sffilffi bodywork
the external skin of a vehicle;usuallyconsistsof severalpanels
camber
angle that is inclinedfrom horizontal,usuallyat 90 degreesto the directionof travel,e.g. the camber of a road (theslope of the road across its width)
catenary
downwardcurved line of a cable when suspendedbetweentwo supports
coastal defences
large walls, blocks,etc.,constructedto protectthe coast from sea/oceanerosion
corrode
degradeas a result ofa chemicalreaction,e.g.iron turning to iron oxide (rust)when exposed to water and air
corrosron
result of materialcorroding(seeabove)
derail
come off the rails, e.g.trains can be derailed
detonate
trigger an explosion
fail-safe
cannotfail / go wrong - often used to describesafety systems
horsepower
historic unit of power,has been replacedby Wbtts but still used to describe power output from engines
inaxial
not in a straight line
opposingforces
forcesacting in opposite directions
oscillation
wave pattern
reversethrust
thrust directed in the oppositedirectionto that which a vehicle/aircraftis travellingin, intended to slow the vehicle/aircraft
rpm
revolutionsper minute,used to measurethe speed of rotary motion
sled
vehiclethat slides along (i.e.does not havewheels),e.g.a sled designedto travel over snow
stress
the force(s)exertedon an oblect,e.g.tensilestress in a cable that is being pulled in opposite directions the part of a structurethat is above ground level- the opposite is the substructure
superstructure
Gtossaryof technicalterms
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1.1
suchas redundantsatellites,that litterorbital space.Basedon carefulmonitoringofdebris movements,in the case of an alert the station's anchorscouldbe raisedand the stationcouldbe moved,driven by propellers,to a new location out of harm'sway.
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7.7
Richard: As you can see,we've started work on the substructure, in otherwordsthe part of the structurethats belowgroundlevel.The foundationsare concretepiles.Basically,a pile is a columngoingdowninto the ground.And we're using what we call bored in situ concrete, 1.4 in otherwords,we bore,or drill,a hole in the I ground,and concrete'spouredin in situ,which you Stefan: So, as can see from this crossmeansit's actuallypouredon the construction section,we'vecome up with a completelyunique site, in its final position.An alternativeis to use profile.lt's exclusiveto this companyand unlike what we refer to as ore-castdriven oiles. Preanythingelseon the market. cast refersto the fact that the oiles are made at a factoryawayfrom the site, before being delivered.They'rethen driveninto the ground. Stefan: One of the key advantagesof this new They'rehammeredin with a pile driverwhich, form is that it dramaticallyreducesvibration, put simply,is iust like a giant hammer.And they which was alwaysa problem before.Obviously, don'tiust drive in piles,theydriveeveryone machineslike thesecan neverbe entirelyfree mad with the constantboom-boom-boom all from vibrationbut the newdesignruns extremely day long.So, thankfullyfor our ears,we'renot smoothly. usingthat technique.Instead,we'reboringthe just piles.The pile augeroverthere is effectively 3 like a giantdrill.As it drillsinto the ground,we Stefan: Another advantageof the new profile is pumpa specialliquidcalledbentoniteinto the that it's considerablylighter,due to the reduced hole.Essentially, it'sa kind of clay suspension,a area of the overallsection.So comparedwith our sort of mud. And that oreventsthe walls of the previousrange,its highlyefficient,especiallyin holefrom collapsinginwards.So whenthe hole's applicationsthat requirecontinualstartingand finished,it's full of bentonite.lt looksjust like a stopping,wherelow inertiais important. big muddypuddleon the ground.Obviously,it's L not a good idea to step in one, like a colleague Stefan: We're still conductinglong-term of mineoncedid. and then had to drive homein reliabilitytests, but trials so far suggestthe his underpantsfor a changeof clothes.So, once designis exceptionally durable,primarilyas a the hole'sbeen boredand filledwith bentonite. result of the low vibration levels.We exoect it they lower in some steel reinforcement.And then to be significantly more reliablethan rivalunits concrete'spumped in. And becausethe concrete that are on the market,whichis obviouslyan is denserthan the bentonite,it displacesit. So, in importantsellingpoint. simple terms, if you picturea glass full of water and imaginepouringconcreteinto the glass,the I1.5 water would overflow and you'd end up with a glass full of concrete.So, that's piling. lf anyone Richard: lf you'retalking to non-specialists,and has any questions,by the way,just ... you start usingjargon,then to youraudience, 1.2 it'siust goingto soundlike nonsense.That's James: The engineeringchallengeof connecting one oroblem.Anotherrelatesnot so muchto I2.1 a satelliteto earth usinga cable is, obviously, language,but to the complexityof the technology lrina: The only way to assess the environmental significant.In order to support its own weight, you'retalking about. Even if you use everyday impact of a given material properly is to carry and be securelyattachedat eachend,the cable |anguage, the engineerin€ conceptitse|fmight out an environmentalaudit and analysethe total wouldrequirea phenomenalstrength-to-weight still be difficultto explain.And that can makethe impactof that materialon the environment. ratio.Carbonnanotubematerialsmight,one subiectvery heavygoing,and quitedull,which I emphasisetotal impact becauseit's all too day, be up to the iob. And l'll talk about those in is obviouslynot what you want. However,I think easy to judge materialsand productson detaillateron. How couldvehiclesbe raisedinto it's important not to oversimplifythings.There's single aspects of their ecologicalimpact. As an space,up the cable?Well,usinga self-contained nothingworsethan beingspokento as if you'rea example,if we comparetraditionaland energyenergysourcewouldbe problematic,due to the child.Youdon'twantto soundpatronising. savinglightbulbs it'stemptingto say energyweightof fuel or batteries requiredto power the savingones are better becausethey consume vehicle.There are two possible ways round this I1.6 less energy.In fact, that's only part of the picture. problem:transmittingelectricitywirelessly,or That'sjust the in-use phase.You also need to Richard: lt's obviouslybest to use everyday usingsolar power.The first techniqueis only in considerthe pre-use phase - in other words,the languageas far as possible.But I don'tthinkthat the early stages of research.The secondwould environmental impactof miningthe materials meansavoidin€ jargonaltogether.l find the best allowthe vehicleto ascendonlyvery slowly, used to make the bulbs, of transportingthose is to approach,so as not to soundpatronising, thoughthis wouldn'tnecessarilybe a problem, materialsto the factory,of manufacturingthem use a certainamountof technicallanguage,and as the car could be controlledremotely,allowing etcetera.Then there'sthe post-use phase.How then immediate|yafterwardsgive strai€ h tfoMard it to transportpayloadsas an unmannedvehicle. explanationsof what it meansusingeveryday easy is it to recyclespent bulbs? And when you start to considera||of these factoís,suddenly words.When it comesto explainingtricky I 1.3 the comoarisonbetweenclassic bulbs and technicalconcepts,a good techniqueis to make James: The ofthore base station would be their energy-savingequivalentsbecomesmuch comparisonsbetweenthe technicalpoint you're supported by a floating structure,which could less clear-cut.Some of the materials used in trying to illustrateand things from everydaylife be attachedto the seabed by anchors.Payloads energy-savinglights are problematicfrom an that peopleare familiarwith,to helpthem paint could be carried from the shore to the station standDoint. both in termsof a picturein their minds.And thento help lighten environmental by ship beforebeingliftedinto orbit.The main acquiringthem and recyclingthem.So the point thingsup, and stop thingsfrom soundingdull,I advantageof a floating mobile station, rather is, it's essentialto look at the whole picture.And think it'sgood to use a bit of humouras well,and than a fixed base on land,wouldbe to help doingthat can be quitea complextask,as we'll maybe a few amusinganecdotes. reducethe risk of a collisionbetweenthe cable see lateron. and one of the manylumpsof spacedebris, Paula:Obviouslynavigationis the primary applicationof most GPS devices. José:Sure. Paula: Then you'vegot associatedapplications, uses that are related to navigating,such as tracking systemsyou can use for monitoring deliveryvehiclesand findingstolencars,that kind of thing. José:Mm. Paula: And then there are more creative features.A good example would be on a boat CPS, you get drift alarms.So if the anchorstarts to drag and the boat starts moving,there's a setting on the cPs that allows it to detect the movement,and an alarm soundsto warn you, and preventsthe boat from driftingunnoticed. José: I see. Paula:Or anotherexampleon boat systemsis man overboard buttons.So if you're sailing along and someonefalls into the sea,you hit a button, whichlogsthe positionand ensuresthat you don't lose track of where you were,which then enablesyou to turn roundand come back to the same pointand find the peBon. José:Right. Paula:So, theseare the kindsof applications we want to develop,more specialised,and more creative. José: So, effective|y'you're not ta|kingabout What you'rereallylooking technicalinnovations. for is innovativeways of actually using the technology. Paula: Precisely.Because these days,from the end-userspointof view,accuracyis no longer the mainsellingpoint.Most devicesare accurate enough.The key is to makethem more useful.So in termsof development, that'sthe kind of ...
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2.2
Sophia:OK, so steelbodyworkversusaluminium bodywork. Fete: What about pre-use,then? Sophia:Well,I think it takesa lot of energy to producealuminium,comparedwith steel, becausealuminium'smade by electrolysis. Pete: Yeah.So steel's better,presumably. Sophia:I thinkso, yeah.But, hangon a minute, withaluminium,it dependshow muchis derived from ore, and how much is recoveredfrom recycledmaterial.As far as I know recycling aluminiumtakeslessenergy.So I'm not really sure. Pete: Presumably,it'll be mixed, won't it? For a givenbatch,there'llbe so muchnew material, and so muchrecycledmaterial. Sophia: Probably,yeah.OK, so that needsto be researched, then. Pete: ls car bodyworkgalvanisedwhen it's made from steel? Sophia: Um ... good question.I'mnot sure. Pete: lf it is, if it has to be coated with zinc, then that would take extra materialand extra energy. So that'san importantconsideration. Sophia: Mm, true.OK, so that'sanother questionto note. Pete:Thenthere'sthe energyconsumedwhen they'retransportingbulk metalto the car plant. Sophia:Presumablyaluminiumtakeslessenergy to transport,beinglighter. Pete: I'd say so, yeah. Sophia:OK. What about manufacturing? Pete:Well,aluminiumwouldbe lighterto handle, wouldn'tit? lt probablytakeslessenergyto cut, as well. Sophia:Yeah.Not surewhetherit takesless energyto weld, comparedwith steel. Pete: Cood question.Anotherthingto checkout. Sophia: Mm, what about in-use,then? | assume aluminium'sbetterbecauseit's lighter,so you consumelessfuel. Pete:Yeah.And it shouldlast longer,as well. Sophia: Mm, is that an environmental consideration, though? Pete:Well,yeah,becauseif thingslast longer, they need to be manufacturedless often. So you use ressenergy. Sophia:True.But then,is the lifespanof a car determinedby the lifeof its bodywork? Pete: Ah. Cood point. Sophia: lt's usuallydeterminedby the chassis,or the engine,isn'tit? Pete: ls it? Sophia: Mm, anotherone to be researched. Pete: OK, what about post-use,then?
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2.3
Margit: So, in termsof the maincomponents, the conductor,at the centre,is copper or aluminium,dependingon the model.That's then coatedwith polyethylene insulationand surroundedby steelwire,whichprovidesthe armouredprotection.As the steelobviously needs to be protectedfrom moisture,there'sa plasticwaterproofmembranearoundthat.Then, the wholething'ssurroundedby an outerjacket which,again,is in plastic-based material.
J
2.4
Toby:That'scertainlya scarylookingcollection of tools. Esther;Yes,someof them do look quite menacing,don'tthey? Toby:ls that titanium?The drill handle? Esther:Um ... yes. Toby:I'man engineer,that'swhy l, um ... Esther: Oh, I see.Yes,titanium'sgreat. lt's expensive,obviously,but very light.That's the big advantage.ldeally,you want it to be lightweight,to give you better control. Toby: Nn. Esther: These are the most impressivethings, though,the burs on the end.The latestones can rotate at over half a million revs oer minute. Toby:Nn. Esther: They'recoated with tungstencarbide, whichI thinkis one of the hardestmaterialsin existence,isn'tit? Alongwith diamond.That's also used. Toby:Nn. Esther:The key requirementis abrasion resistance,of course.Obviously,they need to be verydurable.And you don'twantthem snapping, either.The last thing you want is a brittle material.Apparently,that was the troublethey had in the past,makingthe bur toughenoughso it didn'tbreak.I think part of the problemwas heat,as well.Drillinginto a toothat highspeed, you obviouslyget a lot of heat build-up.You need a good degreeof thermalstability. Toby:Nn. Esther:See what I mean?Youcan actuallysmell burning.And that'saftera few seconds.lmagine the heat build-upafterseveralminutes. Toby:Nn.
J
2.5
Tom:Speakingas an engineer,Louisa,my viewis that all the materialswe use shouldbe genuinely suitablefor makingwatches,and notjust chosen as marketinggimmicks.We'reoftenguilty,in my view of usingexotic-sounding materialsthat are not particularlysuitablefrom a technical standpoint. Louisa:Yeah,I knowwhatyou mean. Tom:A good examplewas that debate we had on whetherto use submarine-grade steel in some models,to givethe impressionthat they're exceptionally resistantto water.OK, submarine steel'sgood at withstanding the pressureof beinga mile beneaththe sea. But it's heavy.lf it's not coated, its corrosion resistanceis not that good,at leastcomparedwithother metalslike titanium.lt's also fairlypoor in termsof looks, in my view.Water resistanceisn't a questionof metalquality,it'sabout the qualityof the joints and seals you use. So, as a watch material, for me,it's not at all suitable.Tremendously marketable. I'msure,but ... Louisa:Hm. No, I take your point.But I think it's fair to say that we've neverchosena materialfor marketingreasonsthat'sinsufticiently durableor not adequatelybuilt in any way. Tom:Oh, no. No, if anything,it's been the reverse.Wb'veused materialsthat are over the top, so theycan be describedwith superlatives in advertising. Louisa:Hm. ldeally,we shouldbe usingstuff that's good for watchesand good for marketing as well.
Tom:Sure.But that'seasiersaid than done. I mean,a lot of the materialsthat are ideal for the job, in terms of scratch-resistance, shockresistanceand all the rest of it, are either pretty ordinary,or theircompositionsare relatively complex,and they'vegot complicatednames whichmeansthey'renot all that good for marketing.That'sthe problem. Louisa:Sure.But the other problemis, consumersare not technicalexperts,and they makechoicesbasedon their impressions, rather than basedon facts.Thats a hard commercial fact,as hard as submarinesteel. Tom:No, I acceptthat. Louisa:So what shouldour approachbe? lt's obviouslynot an easyquestion...
I 2 3 4 5 6
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2.6 not particularlysuitable exceptionallyresistant not at all suitable tremendouslymarketable relativelycomplex not all that good
3.1
Jan: Whenyou look at the varioustypesof plugs and socketsin differentcountries,most designs have a basic layout that's existed for decades, in termsof the waythe pins are laid out, and the profile of the pins. And as a manufacturer, the positionof our companyhas alwaysbeen, basically,to accept that we're stuck with several standard configurations,and to effectivelysay to customers,we produceall the mainformats - take whicheverone you want. Howeve( as I'msureyou know manycountriesuse plugs and socketsof more than one format.And this leadsto a comparativesituation,with some configurations becomingmore popular,and othersprogressively beingabandoned.This is particularlytrue in countriesundergoingrapid economicexpansion.And becauseof this process of selection,we're finding that big customersare increasingly askingus whichof the standardplug and socket formats in current use we recommend as a manufacturer.Which are the best from a technicalstandpoint?Up until now we haven't had a standardisedcompanypolicyto allowus to respondto that question properly.But this projectaims to formulatea companypolicythat allows us to say these are the configurationswe recommend,and theseare the technicalreasons whywe recommendthem.
-3.2 I Erin: On this one,thereare circularpins for live and neutral.There'sno earth pin. This is quitea commonformatin Europeand Russia.lt's also quitewidelyused in India. Erin: Here,you'vegot circularslotsfor liveand neutral.And the earth slot's got a flat base with one side roundedoverto form a semi-circle. This type's only used in a few places. 3 Erin:This one has rectangularbladesfor live, neutraland earth,in triangularconfiguration. This is the standardin the UK and lreland,and a few other places,Malaysia and Singapore,for instznce.
Audioscript
87
TL
Erin: This plug has got circularpinsfor liveand neutral,and it has a cylindricalslot to receive the earth pin. lts quitecommonin continental Europe,and in parts of Africa. irin: ns you can see,thereare circularpinsfor live,neutraland earth,and the pins are arranged in linearconfiguration. This is not a very commonlyusedformat. o
Erin:This is the standardin North America,and ouitecommonin Centraland SouthAmerica. Used in Japan,as well.Thereare flat bladesfor live and neutral,and a roundpin for earth,and they'relaid out in triangularconfiguration. So, an extremelywidelyusedformat.
I3.3 rectangle rectangular triangle triangular cylinder cylindrical line Iinear
r
I3.4 Erin: In this configuration, there'sa circularslot at the top. lt's obviouslya blind hole,it doesn't go right through.And that's designedto receive the earth pin, whichis mountedon the faceof the socket.Thenthereare two plasticridges, one on eitherside of the plugcasing,and they slot into correspondinggroovesat each side of the socket. In addition. the centre of the socket is recessed.So rather than being flush with the front of the socket,on the same face, the circulararea that receivesthe plug is set back from the surroundingcasing,in a recess about I 5mm deep.The liveand neutralsockets are also equippedwith covers,just insidethe opening.Thesecoversonly open whenpressure is appliedto both by the two pins of the plug simultaneously. So we needto look at the advantagesof this configuration...
I3.5
Andy: In this formatthe plugslots into the recess in the socket.That allowsit to fit in reallytightly, comparedwith otherdesigns.P|us,theserid€ e s and grooveson the sides increasethe amountof friction.That helps it to resist pullout forces even more,so it won't fall out of the socket. Karin:Yeah,but at the end of the day,how securelydo you want it to be retained?lf it's held in too hard,that makesit difficultto pull out. Andy: That's true. Karin: Plus,it couldbe dangerous.lf you're vacuumingenthusiastically to loud music,let's say, and you pull the cord, you actually want the plugto pull out, don'tyou? Otherwiseyou might rip the cable halfwayout of the plug,or the appliance. Andy: So, really,we need to comparethe pullout resistanceof all the formats. Karin: And determinewhat the ideal resistance is. Andy: Yeah.OK. Erm,what else can we say about this one?
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Karin: Well I guess another advantageis, given that the plug'sin a recess,if it gets pulledout just a fraction,and the pins are still live,nothing can physicallytouchthem. Andy: So you think that's more effectivethan havinginsulatorsroundthe tops of the pins? Karin: I'd say so, yeah. Andy: This one'salso got coversinsidethe live and neutralslots. Karin:Thats a standardfeatureon moreor less everyformat,though,isn'tit? Andy: Yeah.But I think it's somethingwe should look at. I mean,it's obviouslya good thing. Anythingthat stopschildrenfrom stickingthings in is obviouslya good idea.The only problem with this system is, if the mechanism'stoo sensitive,it makesit difficultto insertthe plug, sometimes.And that makesit easyto damage. Karin: When people try to force it. A n d y :E x a c t l y . . .
Audioscript
3.6
Evan:Most of what we do is sheetmetal working.We don't do foundrywork - you know, castingand that type of thing.That'sobviously a differentdiscipline.But apart fromthat,we're equippedto do most thingsto do with metal bashing. Mr Barrett: That'sthe technicalterm for it, is it? Evan:I'm not surewhatthe technicaldefinition of metalbashingwouldbe. A collectiveterm for hammering,grindingand generallymakinga lot of noise,probably. Mr Barrett: lt's actuallynot that noisyin here, is it? Evan:No, it's not too bad. We had a specialist firm come in a whileago to measurenoise levelsat each machine- you know for health and safety regulations.A lot of what we do isn't all that noisy.Thingslike drillingand milling machinesare not too bad, relativelyspeaking. Anythinginvolvingabrasivestendsto be noisy, thingslike grinders,evenif they'reonly hand tools.And that big press over there makesa loud bang whenthey'reshearingsteel.lt certainly savesa lot of time,though,comparedwithflame cutting,or sawingwitha grinderblade. Mr Barrett: So, it's a guillotine? Evan: That'swhat we use it for mostly,yes.
-3.7 Evan: So we use high-pressurewaterjetcutting quitea lot. The good thingabout it is you don't need to do any finishingafterwards.The edges are virtually perfect.So they are especiallygood when you have intricateshapes. Mr Barrett: Whichwouldbe difticultto finish otherwise. Evan: That's right. Mr Barrett: Saw blades are obviouslyuseless Whenyou'recuttin€ curvedshapes. Evan:That'sright.And whenyou'reusingany sort of abrasivetechniquefor cuttingmetal, it inevitab|y € e ts hot.And that can a|terthe propertiesof the metalaroundthe cut,whichcan be a oroblemin somesituations. 3 Evan: The other problemwith abrasivecutting is it exerts shear forces near the cut. So sawingis not the best solutionif you wantto avoidaltering the material.
Mr Barrett: The same appliesto guillotining, presumably. Evan: lt does, yes. IL
Mr Barrett: lt's amazingto think that a waterjet can cut throughsteel.You couldimaginewatercuttingtimberor relativelysoft material,but ... Evan: No, it's ideal for metals.Actually,lt's not .iustwater that's used.They sometimesadd an abrasive powderto the water to increasethe cutting power. Mr Barrett: Oh. I didn'tknowthat. Evan:The water'sobviouslyconcentratedinto a veryfinejet. Dependingon how it's set up, it can take out lessthan a tenthof a millimetre. sometimes. Mr Barrett: Really?
I3.8
Pedro: So, basically,our obiectiveis to get key suppliersmoreactivelyinvolvedin the design process.So ratherthan us goingto a supplier and saying,we wanta specifictype of bolt or screwor rivetfor connectingthesecomponents, can you give us a price? We want to be able to say,we needa wayofjoiningthis part to this part, what'sthe best way of fixing them to each other? Alicia: OK. Pedro: So it might be that you say,well, actually, insteadof boltingthis onto the machine,what about usinga weld?Or insteadof rivetingthese, howabout bondingthemwith adhesive,or fixin€ themon with some kind of clip,or whatever, whatever'sthe most cost-effectivesolution. Alicia: Right.But, obviously,we'rea supplier of mechanicalfixings,so we can only providea mechanicalsolution.So if you ask us to design someioints,whichis obviouslyquitean involved .iob,and then,afterall that,a rivalfirm comes alongand says,wellwe suggestweldingit all together,or gluingit togetherfor halfthe price, um, it wouldmeana lot of work for no return.l'm not saying it's a bad idea. lt's just that we would have to be carefulwe coveredour costs. Pedro: I appreciatethat. But the flip side is, we wantto workwithfewersuppliersthan we have in the past.So, overall,that problemwouldbe offuetby the greater volume of work you'd get. Alicia: Hmm.
r
3.9
Lenny:So a typicalclusterconsistsof somewhere in the regionof a hundredballoons.That'susing ordinary-size weatherballoons.With about twentypeoplehelpingit takesan houror so to inflatethem all. Eva:An hour or morewith twentypeople? Lenny:Yeah.lt's prettytime-consuming. Eva:And is eachballoontied on individually? Lenny:That'sthe way it's often done, yeah. Eva: And is the rope just fastenedaround the b o t t o mo, r . . . ? Lenny:Well,some peopleuse plasticcableties. Or you can use tape. Eva:So it's a big.iob,then,puttingeverything together.The harness is suspendedfrom a hundredor so ropes,then.Well,how is it fastened? Lenny:Well, you can put nylon straps beneath the ropes.So you have severalropes tied to a single strap, then each strap is fastenedto the harness. Eva: I see. So it's like a kind of tree structure.
Lenny:That's right. And you have different lengths,so the balloonsaren'tall at the same level,so theyfit aboveand belowone anotherin a round-shaoed cluster. Eva: I see. So you inflate the balloons,keep tying them to the harness,via the straps,and keep doingthat untilyou take off. Lenny: Basically,yeah.The pilot's roped to sandbagson the ground.So the balloonsare addedprogressively untilthere'sa marginal amountof lift.Thenthe anchorropesare released,and up you go, niceand gently. Eva:And how do you controlyouraltitude?You carryballast,presumably. Lenny:Yes.Water,usually.Those big water bags withtaps on, ideally,so it's easyto drain out. Eva: And how do you come back down to earth? Lenny:Well,that'sactuallya reasonfor having Youcan release the balloonstied on individually. them,one by one,whichallowsyou to reducethe amountof lift incrementally. Eva:I see.BecauseI was thinking,surelyit would be easierto iust haveall the balloonscontained withina big net,to makeit fasterto assemble. You know,ratherthan spendingagestyingevery But then if you singleballoonon individually. did that,you wouldn'tbe able to releasethem, wouldyou? Lenny: No. That'strue. Eva:You couldburstthem,somehowI suppose. Lenny:Yeah.I mean,thereare obviouslyvarious waysof doing it ...
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4.1
Joe: I havea questionaboutthe panelson Staircase3. You knowthoseglasspanelsaround the opening,throughDeckC? Linda: Um, yes.I knowwhereyou mean,yeah. Joe: Well,I'vebeen lookingfor a cross-section throughthe deck,at the stairopening.But I can't find one anywhere. Linda:lsn'ttherea noteon the general arrangementdrawing,with a referenceto a sectionon anotherdrawing? Joe: I couldn'tfind one. Linda: I'vegot the deck plansout, somewhere on here.What'sthis?Air conditioningschematic, that'sno good.Ah herewe are.Deck plan.Um, no, you'reright.There'sno sectionmentioned. Joe: I mean.in actualfact.what I needis an elevation,showingall the panelsfrom the front. on the main I thoughtthat mightbe referenced sectionthroughthe stairs. Linda:Thereis a full set of drawingsfor all the internalpanelling,with detailsshowingexploded viewsof all the fixingdetails,and sections throughthe paneljoints.Do you havethose? Joe: Not as far as I know. Linda:And there'sa writtensoecification for the panels,as part of the mainspec.That might specifythe sizes. Joe: Thoseare obviouslywhat I need,then.I want to see how many there are, and what size they are. Have those drawingsbeen issued?
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4.2
Pavel:So how wide is this panelat the top? Joe: Good ouestion.There'sno dimension. Pavel: ls this drawingto scale? lt's one to five. Haveyou got a scalerule? Let'smeasureit. lt looksto be about threehundredmil. Joe: The goldenrule is, you shouldn'tscaleoff drawings,though,shouldyou? Pavel:Well ...
Joe: lt's not so bad if it's actual size.on a fullscaledrawing,but I'd rathernot with this.Let's queryit. l'll givethemanothercall in the office.
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Mei: Basically,the clienthas said theywant a suoerflatfinishoverthe entirefloorarea. That makes it a free movementfloor, where vehiclescan run anywhereon it. But on the manufacturingprocessdrawings,it shows preciselyspecifiedroutes for these automated vehicles.So, technically, it shouldbe a defined movementfloor,where you can just have a few narrowlanesfor the vehicles,whichare superflat, and then the restof the slab is just laid to normaltolerances. the extra Lewis:Right.So you'requestioning cost of doing everythingsuperflat? Mei: That'sthe mainthing,yeah.The other thingis quality.To get the best finishon these superflatfloors, it's better to lay narrowwidths of slab in fairlylong lengths.So, ideally,you want lanes,ratherthan big, wide areas. Lewis: OK. But maybe they want everywhereto be superflatso theycan changethe layoutof the productionline in the future. Mei: Possibly.But evenif theywantto do that,the surfacecan alwaysbe modifiedat a laterdate.lt's a thickslab,so there'snothing to stop them grindinga layeroff the top. In fact, we could increasethe depth of the steel reinforcement slightlywhenwe pour the slab, so there'ssome extra thicknessof concreteover it. so, if theydid Wantto € r ind a thin |ayeroff a sectionin future,theywouldn'thaveproblems with shallowcover. Lewis:Right.Well let'slook into an alternative desi€ n for a defined movementf|oor.
I4.4 I Leo: I'veworkedon projectsin the past where everysingleworkingdrawingis circulated to everyteam - structural,mechanicaland electrical- and lt.iustgetscompletelyout of control.So we wantto avoidthat situation. Engineerl: Sure.But aftersayingthat,if someonehas to analyseeverysinglerevisionto determineexactlywhichteam needsit, thenthat takesa lot of time as well. Leo: Not if there'sa properprocedurein place. As longas we makesurethere's... Leo: This projectstrikesone as prettycomplex, in termsof the amountof integrationand overlap betweenthe differentdesign packages. Engineerl: Yeah. Leo: Particularlybetweenmechanicaland electricalteams so we have to coordinatethat. And it'sobviouslya specialistjob. lt's beyondmy expertiseas the overallprojectmanager.So, in orderto makesurethat we ... 5 Leo: Thinkingabout howthe separatedesign groupsWorkto€ e ther, I don'tWantto re|ytoo muchon scheduledmeetings.We don'twant questionsand problemspilingup, waitingto be resolvedat a meetingin a week'stime,or whenever. Youall needto be talkingto one anotheron an ongoingbasis. Engineer2: I agreewithwhatyou'resaying. Thá troub|eis, Whenyou'retryingto sort oút problemsWithdetails on drawinls and that kind And given of thing,you needto meetface-tó.face. that wó a||Workin separateoffices,it's, you know we can phoneeachother,but ...
Engineer l: Yeah,you still need meetings. Engineer2: Especiallyas there'sso much integrationbetweenthe differentpackages,the pointwe weretalkingabout before. Leo: Well,thereis a solutionto the problem.
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Leo: So, to sum up. As regardsdesign informationflow,all preliminarydrawingsare goingto be shownto the seniorengineerin chargeof eachdesignteam.The seniorengineers then say whetheror not their teamsneedto receivecopiesof later revisions.lf they don't, theywon'treceiveany furtherrevisions.lf they do, they'llbe issuedwith everysubsequent revisionand, later,revlsionsof workingdrawings. To coordinatethe interfacebetweenmechanical and electricaldesign,I'mgoingto appointa mechanicaland electricalcoordinatorresponsible for liaisingbetweenthe seniorengineersin the teams,reportingto me.We'relocatingall three designteamsin a single,open-planofficeso Whenanyone's€ o t a questionor a problem,they can talk to the appropriate person face-to-face. We still havescheduledmeetingsto discuss formalissues,but the emphasiswill be on ongoing,informaldialoguebetweenthe teams.
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Chen:There'sa discrepancybetweenthese detailsthat you mightbe able to clarifystraight away.On the plan of this plate,it showseight bolts.But on sectionA. here.thereare no bolts shownin the middle.So therewouldonly be six, whichobviouslycontradictsthe plan. But as you can see,this plate'sgoingto be boltedto a T profile.So we couldn't put a row of bolts down the middle,becausethey'dclashwith the flange runningalongthe middleof the T.So I'd propose just goingfor two rowsof bolts.The alternative wouldbe to redesignthe T section,whichwould obviouslybe a bigger.iob. Ron: Yes. Let's go for two rows of bolts, as per the sections. Chen:OK, fine.Will you send an emailto confirm that?
I5.1
Sabino:A race is not just a test of speed,but There'san old the ultimatetest of reliability. sayin1,to finish first, first Uou must finish, and it's especiallytrue in enduranceracing.You're not just competingagainstrivalteams,you're also fightingwhat you couldcall engineering enemies,whichcan causepartsof the car to fail,thingslike heat,pressure,vibration,shocks, abrasion- there'scontinualstresson almostall all the nuts and boltson the the components, car.The chassis,engine,gearboxand clutch, suspension,brakes,tyres,wings,coolingsystem - theyall haveto cope with phenomenallevelsof wearand tear.
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Sabino;Just to giveyou some examplesof the typesof technicalproblemswe'vehad so far at this test.on one of the cars' a nut Worked|oose on a radiatorpipe,whichresultedin coolant liquidleakingout. That causedthe engineto Fortunately, startoverheating. the driversaw the warninglightcome on, and he switchedoff beforethe systemhad run out of coolant.Then on the othercar we had a fuel feed problem; the enginecut out on one of the corners.That causedth€ driver to spin off. We Werefortunate' he didn'thit anything.But Whenthe car goesoff the circuit.the openingsin the side podsa|ways
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clog up with dirt. So those had to be cleaned out. Obviously,you don'twant anythingblocking the airflow to the radiators.And then becauseof the spin, the rubber was flat spotted. The tyres weren'tcloseto wearingout, but they still had to be changed,becauseof the flat spots.And then whiletheywere puttingthe wheelsback on afterthat,they had a wheelnut jam, it wouldn't turn.And that'sactuallyhow problemstend to happen,very often.Youget a kind of chainof events,when you feel that everything'sgoing againstyou. Havingsaid that, you couldalso say we were lucky.Fortunately,the radiator problem didn'tcausethe engineto blow up. And afterthe spin,luckilyhe didn'thit the barrieB and bend the suspensionor snap it completely. And even morefortunately, it didn'tcrackthe tub - the chassis.
I5.3 Al: So what does the warning messagesay? Mr Rooney: When you start the engine,it says checkinjection. Al: Right. Mr Rooney: Obviously,it must be some sort of defectin the fuel iniectionsystem.The thing is, though,it only happensintermittently. Sometimes,you start it and there's no message problem,I don't at all. So it mightbe a soft!ryare know.Or maybe it could be a defectivesensor. Al: ls the engineworkingproperly? Mr Rooney: lt seems to be fine, yeah. Al: lt doesn'tappearto be misfiringor downon power? Mr Rooney:No, we haven'tnoticedanything. Presumably,it can't be anythingtoo serious.We thought it was possibly water in the fuel system becauseit's an outdoorunit.But in that case,I assumethere'dbe majorproblemswith it. Al: Has it been refuelledrecentlv? Mr Rooney: Not that recently. Al: And was it refuelledwith dieselstoredin your own tank,or directlyfrom a deliverytanker? Mr Rooney:Froma tankertruck. Al: I doubt it's water.then. if the fuel went in directly from a delivery.You said the warning doesn'tdisplaysystematically? Mr Rooney:No. Al: ln what sort of circumstances does it come up? Mr Rooney:Well,whenyou start it up for the firsttime each day,it comesup. But then if you stop it, and start it again a short time after, there's no message.lt's when it's been off for a long time that you get the warning. Al: oK. So it's certainlya questionof temperature.lt only comes up when it's started from cold? Mr Rooney:Um, yeah.Exactly. Al: Hm, it soundslike it's a faultyfuel pre-heater. It'sprobablyjust one of the pre-heaterplugs that'sgone.lt's only a minorfault. Mr Rooney: Oh, right. So it doesn't need urgent attention? Al: No. lt can be replacedat the next service. Keepan eye on it, though.lf any other problems start to show up give us a call and we'll send someoneover.
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Alan: Hello. Julia: HelloAlan, it'sJulia. I'veiust starteda landinggear checkand founda bit of a problem with some tyres.All the pressureson one of the wing blocksare welldown. Alan: On the same block? Julia: Yeah.On all the otherblocksthey're correct.So it seemsodd that this one groupof tyres,on one corner of the aircraft,are all low. And the strangething is, they'redown by exactly the same amount on every tyre on the block. Alan: I see.You'reright,that is unusual. Julia: The wear rate's consistentacross the wholeaircraft,though.There'snothingunusual about the wear oattern. Alan: Are you sure the pressuregauge is working properly? Julia: Um, well,to be honestyou can tell just by lookingat the tyresthat they'redown. Alan: Right. Let me come out and havea look.
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Paul:OK, let'shavea look at the coolant,first. The level'sOK. Eric:lt's fullof residue,though,by the look of it. Paul: lt looksa bit black,doesn'tit? Timeto changeit, I think. Eric:OK. What'sthe filterlike? Paul: Um ... it looksreasonableto me. Eric: ls it due to be changed? Paul: lt is if we followthe service programmeto the letter.The troubleis, if you do that,you end up wastingparts halfof the time. Eric: We can take it out and give it a bit of a clean.lt'll be alright. Paul:OK. Blades,next.Hm, they look moreor less OK to me. There are no signs of damage. Eric:Yeah.No needto changethose.They'll havemoveda bit sincetheywerelast checked, though.The alignmentwill needto be lookedat. Paul: Sure. Eric: Apart from that, it's not lookingtoo bad.
I6.1 Claudia: So with regard to the capacity,in terms of the numberof peopleit actuallyneedsto carry,what sort of figure are you lookingat? Kevin:Um, 36 is whatwe'reaimingfor. Dave: lf you think we can add a few seats withoutmakingcompromises, then by all means, let'slook at it. Kevin: I think 36 is going to be at the top end as far as size is concerned. Claudia: And as regardsthe graphics,is the video sequencefinalised? Will it be exactlyas it is on this DVD? Kevin:Unlessyou haveany problemsgenerating the physicaleffectsthat go with it, then, yeah, as far as we're concerned,that's it. Claudia:Right,excellent.We can start lookingat that straight awaythen, and get things moving. Um, so regardingthe schedule,then, what sort of timescaledo you havein mind,for the whole project?
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Claudia: In terms of the physicaleffects,to what extent do you want the experienceto be physical?The degreeto which it movescan be variedquiteconsiderably.
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Kevin:Well,I mean,we want it to be physical, that'swhywe'rehavinga dynamicsimulator.But we obviouslydon'twant it to be so extremethat peopleare closingtheireyesand not watching the amazinggraphicswe'vegot. Claudia: Sure. I mean, it's obviouslydifticultto quantifysomethinglike this,in theory sitting in a meetingroom.The only wayto determine what'srightis to actuallysit in a simulatorand experienceit yourself,in practice. Dave: Of course. Claudia: So what I'd suggestis, after the meeting we can strap you into one of our machines,and you can assessthe possibilities. Kevin: Sounds interesting!
I6.3 Rick: lt obviouslyhas to be liftedwitha crane. Gabriella: Yes, but do the slings necessarilyhave to pass under the base? Why not come up with a way of hookingonto the side of the statue? Rick: How? Gabriella:Well,couldn'twe drill into it, horizontally, and insertbars into the holes?Then hookonto the bars. Rick: Peoplewouldsee the holesafterwards, though. Cabriella:We couldfill all the holes,couldn'twe? Surely they could use some sort of filler that's the same colouras the stone. Rick They'd never hide the holes completely, though.lt wouldstill leavemarks,wouldn'tit? | don'tthinkthat wouldbe acceotable. we couldmakesure Gabriella:Or, alternatively, the ho|eswereout of sight.What about dri||in€ into the top, vertically? lf the holes were right on the top, they'dbe lessvisible.Thenthe bars couldbe set in, with liftingeyeson the end. Rick: Hmm. The trouble is. if the bars were set in with resin,they'd nevercome out. They'd have to be cut off,wouldn'tthey?And this mammoth's lyingdown,so the top will probablybe seen,to an extent. Gabriella: True. Rick:To be honest,I don'tthinkwe can envisage drillinginto it. I supposeanotheroptionwould be to use some sort of grab, on the end of the cranejib. You know,like the ones they use for offloadinglorries. So, the statue would be held by friction.But I can'timaginetherebeing anythingcapableof lifting36 tonnes.Especially not somethingthat wide. Gabriella:Hm, no. Haveyou spokento the masonsabout this? Rick: Not yet, no. Gabriella: Why don't we ask them?
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Viktor: So all the steel beams shownon this drawingare goingto be fixed to the walls,bolted throughthe concrete. Raiesh: Right. ViKor: So to bolt through,obviouslywe need holesin the walls.We can coredrill them,with a diamonddrill,whichwouldobviouslybe done afterthe wallshavebeencast.Um, we'ddrill them ourselves,as part of our contract package. Alternatively,the holes can be preformedby puttingplastictubesinto the concretewhen they cast the walls, in which case the contractor resoonsiblefor the concretestructurewould do rhe job. Rajesh: OK.
Ben: Not if they use the smaller-sized bottles. Stephanie:We'llneed to specifythe bottlesize in the orocedure.then. Ben: Yeah.They'llhaveto take care that the bottlesdon'tfall onto someone,as well.That no one'sstandingin the bottomof the silo,while they lowerthem down. Stephanie:True.That'sanotherpointto mention.OK, so accessisn't reallya problem, then.The maindangeris the fact that it's a confinedspace.Especiallygiventhat they're welding,withan oxy-acetylene torch burning, whichwill producea fair amountof COr. Ben: So they'llneeda CO, detector. Stephanie:I mean,to be safe,they'llneedto test the air beforethey go down,anyway.But we shouldprobablyspecifythat they needto keep the detectorwith them whilethey'reworking, and keepit switchedon. 7.7 Ben: Yeah.Anotherhazardis there'llbe metal fumesgivenoff as they'reactuallywelding,which Rosana:Next weekthey'redue to start is a differentproblemto the CO, issue. I6.5 work on the grainsilosin Zone 4. maintenance Viktor: In terms of cost,preformingis obviously Stephanie:Sure.So really,they'llneeda We need to make sure that everyone'saware that ventilationsystemdownthere,some kind of air a lot cheaper,becauseall you needare plastic all thosesilosare classedas confinedspaces. tubes,whichare cheapto buy,and quickto put extractor. go words, no should inside them In other one in. lf we do it that way,it'll be dead easy,and it'll Ben: Probably,yeah.And there'sthe problem And we need to without first doing an air test. cost peanuts.Whereascoredrillingwill be slow of dust,as well.They'llhaveto be very careful well. keep a check on dust levels, as it'll be quitea painstakingjob. But ... aboutthat. lf they'reweldingand there'sgrain Rajesh:But coredrilling'smoreaccurate,clearly. Marc: We'vegot a CO, detector here,haven't dust in the air,there'sgoingto be an explosion hazard. Viktor:A lot moreaccurate.I mean.sometimes. we? you can get awaywith preforming.lf you needto Stephanie:Yeah.Woulda ventilatorclearthe b get withintwentymil, then it's perfectlyfeasible. dust,or make it worse?| supposeif there'sa lot Rosana:lf you walk pastthat machinewhileit's Tenmil is - it's achievable, but it's stretchingit. lyingaround,it'd keep blowingit up into the air, running,and you'retryingto talk to someone, wouldn'tit? Anythinglessthan ten mil, and there'sno way you haveto shoutto be heard.And as a rule of you can do it. thumb,that meansit shouldbe an ear protection Ben: Mm. I'mnot sure. Raiesh:And what sort of toleranceare you area. lookingfor? J 7.3 Marc: Yeah,but the regs differentiatebetween Stephanie:Restrictedareasare placeswherea Viktor:About ten mil. briefexposure,whenyou'rewalkingpast Rajesh:So it's borderline,then. something,and continuousexposure,don't they? seriousdangeris present.So it's essentialthat theseshouldbe kept lockedat all times.Under Viktor: lt's a tall order.The safe bet wouldbe c no circumstances shouldanyonebe able to goingfor coredrilling. Marc: So is it harmfulif it splasheson yourskin? accessthem,unlessthey havea permitto work, Rajesh:The problemis goingto be the schedule, in otherwords,a writtenform givingpermission Rosana:Accordingto the noticeit's an irritant, though. to work in the restrictedarea. and it's toxic. Viktor: Exactly.I mean,to diamonddrill the Lin:And permitsto work,and the keysto Marc: But it's not corrosive? numberof holeswe'retalkingaboutwill take, restrictedareas,can only be issuedby the Not far I'm aware. Rosana: as as u m. . . electricalsuoewisor? Marc: So you don't need gloves and eye Rajesh: lt'll take foreverand a day,won't it? Stephanie:That'sright.So that one individual protection you rest of it? lf and masks and all the Whereasif they'repreformed,they'dbe readyas is responsiblefor electricalsafetyfor the whole get any on yourskin,you.iustwashit off. soon as the wallsare cast. plant.Only that personis authorisedto issue Viktor: But if halfof them are in the wrongplace, Rosana:Hm, I'mnot sureabout that. oermits to work. it'llcost an arm and a leg to put them right. o Lin: Presumably,it's importantthat permits Becauseif they'rewrong,it's not just a question Rosana:We needto enouirewhetheror not are issuedeverysingletime someoneentersa of drillingnewones in the rightplace.lf they're this maintenance involveswelding.Thereare restrictedarea - eachtime they do a newjob, slightlyout of position,they haveto be filled forklifttrucksgoingthroughthat area carrying they needa new permit. in, first,with cement,to avoidhavingtwo holes flammableliquids.lf thereare goingto be any Stephanie:Exactly.They shouldn'tbe issuedfor overlapping. so puttingthem rightis easiersaid naked flames or sparks,we'll need to put a any longerthan a full shift. than done. properprocedurein place. Lin: OK. Rajesh: Sure. So as I see it, the key issue here,in Marc: Right.l'll get in touchwiththeir people, Stephanie:And it's crucialthat there'sjust a is the tolerance.lf the holes terms of feasibility, then. singlekeyto each restrictedarea.The whole can be bigger,and there's more play for the idea of havinga lock-outsystemis to ensure bolts.we won'thavethis oroblem. 7.? at that only one personhas accessto switchgear Stephanie:So in termsof access,theoretically, any giventime.So whateverhappens,someone f 6.6 there'sa risk of someonefalling,as theyclimb while cannotswitchon a circuitat a switchboard Marta: So, to be clear about how far we can go up a silo,or downinto one.But there'salways somebodyelse is workingon it somewhere else withthis redesign,we'renot aimingto reinvent an externalstaircasewitha guardrail,leading in the plant. the wheel,in termsof the maincomponentsand to the top, and thereare permanentladders, Lin: Mm, if we imaginea technicianneedsto, how they fit together.The reasonsfor that are with protectivehoops around them, fixed to let'ssay they'regoingto changea motoron firstly,from a hardwarepoint of view,the existing the insides,leadingdownto the bottom.So one of the lines,theyget a permitto work,and design has provedto be effective.And secondly, workersshouldbe able to accessthesesilos obtain the key to the switchboardfrom the we don't havethe resourcesat this oointin time fairlysafely.The big problemwill be gettingthe electricalsupervisor.Then they take the key, to makefundamentalchangesto the production weldingequipment,the gas bottles,downinto unlock the door to the switchboard,switchoff orocess. the bottom. the circuit-breakerfor the motor.to isolateit. Engineer l: So the overallinternallayoutneeds Ben: They can be lowereddown by rope. then lock the door again. to remainthe same? Stephanie: Won't they be too heavy?
Viktor: Now the oroblemis, theseboltswon't havemuchplay. Rajesh:Howdo you mean? Viktor:Well,they'vegot to fit quitetightlyin the holes,so they won'tbe able to movemuch.There won'tbe muchspacearoundthem,to adjust their oosition. Rajesh:I see. Viktor: So that meansthe holeshavegot to be positionedvery precisely.lf they'reslightlyout of positionon the wall,theywon'tmatchup with the holesthat havebeen pre-drilledthroughthe steel beams,at our factory. Raiesh:Sure. Viktor:That'sthe main technicalissue,in terms ofdecidinghowwe form theseholes.Obviously, the technicalside'snot the only consideration. There'salso the questionof timescales- given that thereare a lot of theseholesto do. And, obviously,the questionof cost,as well.
Marta: Yes.We'relookingfor an evolution, ratherthan designingthe wholethingfrom thereis roomfor the groundup. Presumably, improvement? Engineer2: Well,this modelhas been revamped once before.of course.But. no doubtwe can refineit a bit more. Marta: However,given that softwareredesign isn'tan assemblyissueand has beenthe Achilles heelof the exlstingmodel,it wouldmakesense to rethinkthat wholesystem. Engineerl: So for software,back to the drawing board,then? Marta: Well, er, whateverwe do, we need to makea quantumleap.Whetherthat means designingthe systemfrom scratch,I don't know. We needto makethe wholething muchsimpler to use.
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Stephanie:That'sright.Then,whilethey're working,it's vital that they keepthe key on them continuously.
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Krisztof:The main hazard,whenmanoeuvring a helicoptercloseto powerlines,is the risk of a collisionwith the line.So beforecommencing work, it's essentialfor the crew to have detailed informationaboutweatherconditions,especially wind directionand speed.Operatingin very windyweatheris obviouslyout of the question. The pilotsinvolvedin live linework are highly trainedand experiencedand theirexpertiseis arguablythe crucialfactorin ensuringsafety. Anotherhazardis snagging,as at certaintimes the platformwill momentarilybe attachedto the powerline and to the helicopter,leavingthe that aircrafttethered.lt's essential,therefore, the cable is equippedwith a tensionrelease mechanism,so that if the helicopterpullsaway suddenlyfor any reason,the cable can break free.To oreventelectrocutionand burns from arcingcurrents,the crewon the platformwear threads hot suits.Thesehavestainless-steel whichchannelthe electricityaroundthe technician's body,allowingthe 400,000 volt supplyto flow betlveenthe powerline and the platform.The suitsalso havea fireprooflining,to provide protectionfrom heat. And eye protection is worn,as a protectionagainstflashesfrom electricarcs.Again,trainingis one of the key factorsin ensuringsafety.As a precaution againstmechanicalfailure,the suspensioncable, platformand all associatedequipmentare inspectedbeforeeachoperation, systematically to checkfor damage.And the helicopteris One maintainedin linewith aviationregulations. additionalprecautionis takenregardingthe craftare engines:only twin-engine helicopter's usedfor live linework,so that if an enginefails, the pilot can still land safely.
3 Petrus:Youshouldtake carewhenyou're cleaningbelowthe guillotineblade,because there'sa dangerthat the bladecouldcome down.Beforeyou cleanit, you shouldalwaysset the control lever in the Blade Locked position. And you shouldwear protectivegloveswhile you'recleaninglt, becausethe sump belowthe bladecan containsharDmetaloff-cuts.
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Roland:We knowthe clientis a verygreen orientatedcompany,very big on all things environmental. Saskia:Absolutely. Roland:so ener€ y savingobvious|yneedsto be in the design.Clearly, an importantconsideration it's a big subject,and somethingwe needto look into in depth.But one specificaspectof it where I thinkwe can makea real differenceis withthe with BuildingManagementSystem- specifically, the way we use presencedetectors.And I'vehad a coupleof ideasthat I'dappreciateyourviews on. Saskia: Sure. Roland: I thinkwe shouldput two totally differentdesignoptionsto the client.Optionone is to havea buildingwith maximumautomation. So withthe maximumautomationoption ...
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Roland: ... withthe maximumautomation option,we put presencedetectorsall overthe place,and link them to as manysystemsas possible.Not just the usualsystemsthat activate the lightswhenpeoplewalk into roomsand turn them offwhenthey leave.We coulduse presence detectorsto control other systems,as well, like the blindson the windows.So, if it's the middle of summer,and a presencedetectorsensesthat everyone'sleft a meetingroom, a temperature sensorpicksup a positivereadingfrom sunlight J7.5 comingthroughthe glass,the electronicsactivate comedown the blinds,whichautomatically lsobel:The focusof the coursewill be on your and blackout the room.Thatwouldlimit heat personalobligationsin terms of lookingafter absorDtionand reducethe load on the airyour own safety,and the safety of others.That savingenergy. conditioning, meanswe'llbe focusingon specificsafety For instance,we'llbe lookingat Saskia:OK. regulations. personalprotectiveequipmentthat'scompulsory. Roland:Or in winter,if the blindshad been Or activitiesthat are prohibitedin certainareas, pulleddownin the meetingroomthe evening of the obligations suchas smoking.The ma.iority before,the next morning,the sensordetects ln other we'lldeal with are legal requirements. sunlight,and triggersthe blindsto raiseand let part of words,they'restipulatedby law as in as muchsunlightas possible,contributingto healthand safetylegislation.lf you contravene the heating.And therecouldbe temperature it's not the same as thesekindsof regulations, to determinewhichroomsare the measurements turningup for work late,or merelybreaching a circulation Warmest,and thosesensorsset oÍÍ your contractof employmentin someway.lf systemto distributethe warmair throughthe someonefailsto complywith healthand safety building,into the corridor,or into roomsat the regs,they'rebreakingthe law.lt's as simpleas other side of the building,or wherever. you're it is an all awareof that, but that. I'msure Saskia:So, we'duse presencedetectorsand importantpointto emphasise. heat sensorsto regulateas manysystemsas oossible? Roland:Yes.Well,that'swhatwe'dhavewiththe maximumautomationoption. Petrus: lf there'sa fire,you shouldn'tuse on this machine,because waterextinguishers it containselectricalcircuits,and it can cause Roland:The secondoptionis this.lt's a very You shouldonly use a carbon electrocution. consciouscompany,so I assume environmentally dioxideextinguisher. that green attitude is shared by all the staff.lf that's the case,why is there a need to automate everythingin the buildingwhenmostthingscan Petrus:When you lift this machine,it's essential be operatedmanually?Why doesn'tthe bossjust that you shouldonly use the two liftingeyes circulatean emailremindingpeopleto switchthe markedin red. No other parts of the frameare lightsoff whentheygo out and tell them to lower load-bearing, so you mustn'tuse them as anchor the blindswhenthey leavea room in summer,so oolnts. | mean,you'dsave it helpsthe air-conditioning?
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electricity, becauseyou wouldn'tneedto control and the moneyyou all the systemsautomatically, manualcontrols savedby buyingold-fashioned insteadof hi-techelectronicscouldbe spenton plantingtreesor something.I mean,it sounds s i m p l eb, u t . . . Saskia: Mm ... it's a very interestingidea.We haveto bear in mind.of course.that the client'sa manufacturer of hi-techelectronicgizmos.I'm not sure howthey'dfeelabout ...
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Jochem:The obviousdangerhere is that you couldget a build-upinsidethe vesselif there'sa blockagefurtheralongthe pipe. Katerina: So the vessel needs a safetyvalve? Jochem:Yes,and maybesome sort of warning system,as well.lt couldbe somethingthat's trlggeredby a differentialmeasurement.So if there'sa hi€ h readingin the tank,and a |ower one furtheralong,you'dknowtherewas a blockagesomewhere. Katerina: We'll need a systemfor monitoringgas consumotion. Jochem;What,a meteron the supplypipe? Katerina:Well,yes,that wouldmeasure But we also need cumulativeconsumption. to monitorthe actualrate of consumptionat differentpointsin time duringthe reaction cycle.And if we havethose two parameters,we can then determinethe frequencyof peaksin whichis the third parameterwe consumption, neeo. Jochem:So that'sa softwareissue,then.As longas the cumulativevalue'sbeingrecorded against the timescale,we can plot the rate of consumpuon... 3 Katerina: The reactionthat takes place is going to be exothermic.But the amountof heat will partlydependon how hot the gas is whenit entersthe vessel. Jochem:Yes.becausethat input heat can be adjusted. Katerina:Exactly.So we'llneeda sensornext to the valveto measurethe inputvalue,as gas comesin, and then anotherto give us an output value.Then,we can workout the optimuminput temperaturefor the gas.
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Helen:One of the biggestheadachesin powergenerationis the factthat electricity So in order consumptionfluctuatesconsiderably. to maintaina continuoussupplywe haveto make continualchecks,and adjustthe powerload we generate.To help us plan thosead.iustments, we forecastfluctuationsin demand,so that we can anticipatepeaksand troughs.We base these forecastson a numberof differentfactors.One of them,one of the most importantones,is Duringperiodsof very cold or very temperature. The increasein hot weather,demandincreases. demandis obviouslydue to millionsof electric radiatorscomingon whenit's cold,and airconditioningunitsworkinghardwhenit's hot. Another factor,a key factor which increasesor decreasesdemand,is whetheror not it's light or dark in the morningand evening- obviously So those are that dictateslightingconsumption. the two malnseasonalfactors.Theygenerallygo so on cold,dark,winterevenings, hand-in-hand
I the rise in demandis significant, comparedwith warm,light,summerevenings.We also take into accountwhat day of the weekit is, particularly whetherit's a weekdayor the weekend. Cenerally,demandrisesduringthe week,when factoriesand oÍficesare operational,and then decreaseswhena lot of them closeat the end of the week.So demandfallsat the weekend. Thoseare variationsthat take olacewithina givenweek.Duringany givenday,thereare factorssuchas mealtimes,whenelectricovens are switchedon - obviously,that causesa jump in consumption.Evencommercialbreaksduring popularTV showscan causeblips in demand. Therecan be a suddenrise whenpeoplerush to switchkettleson, or heat up snacksin microwaves, and then a suddenfallshortly afterwards.
I8.6 Helen:Becauseelectricityconsumption f|uctuates acrossa significantran€ e , in orderto copewith peakdemandour maximumcapacityis equivalentto the top of that band of fluctuation. That meansthat duringoff-peakperiods,we havesignificantsparegeneratingcapacity.Now, in an idealworld,it wouldbe good to use that spare capacityto generatepower and store it for use duringpeaktimes.Unfortunately, as you probablyknoWelectricalchargeis extremely difficultto storein largeamounts- you can't just chargeup hugebatteries.So we use an innovativetechniqueto storeup powerpotential duringoff-peakperiods.
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8.7
Helen:The conceptof pumpedstorageis relativelysimple.Duringoff-peakperiodswhen main power stations have got spare capacity, some of the extra power they produce is used by pumpedstoragestationsto pumpwaterfrom a lowlevel reservoirup to a high-levelreservoir, wherethe water'sstored.lt's then heldthere untilthere'sa peak in demandat some pointthe next day.At that point,the water'sreleased,and it flowsdownthe pipes,drivingturbinesat the bottomwhichgenerateelectricity. Obviously,the stationcan only run for a fairlyshortperiod,but it's sufficientto coverthe peak in demand.Then, as soon as there'sa dip in demand,the water can be pumpedback up and held readyfor use again.So the effectis to smoothout fluctuations in the outputof the main powerstations.Some of the main stations'sparecapacityis usedwhen therewouldbe a troughin the demandcurve,at night.The peak daytimegeneratingcapacityof thosemain statlonscan also be lowerbecause the pumpedstoragestationsare thereto back them up whenthereare blips in the demand curve.
I8.8 Gerry:Ouestionnaires like this drive me mad. I mean.look at this firstouestion.What percentageof my time do I spenddoingtechnical tasksthat use my skillsextensively?Howare you supposedto put a numberagainstthat? Eleanor:Youonly needto givea ballparkfigure. Gerry: I know but even so. lt's difficultto say,off the top of my head. Eleanor:lt's easierif you compareit withthe secondootion. Gerry: Doingtasksthat a lessqualifiedcolleague coulddo. Well,let'ssay roughlyhalfand half. Eleanor:Are you sure?Aren'tyou the least qualifiedpersonin this department?
Gerry: Do you know,I knewyou were going to say that. Numbertwo - technicaltasksthat add valueand tasksthat don'tadd value,suchas admin.Add value?What'sthat supposedto ... Eleanor:Well,do you not do someadmin?Or do you spendall of yourtime doingproductive things? Gerry:Well,no. Nowherenearall of it. Eleanor: Right.So is it fifty-fifty? Gerry:Um well,no. I spendmore time problem solvingthan I do on admin.Thankfully. Let's say somewherein the regionof two thirds.So, about a thirdon admin.Three- tasksthat are purelytechnicalversustasksthat relateto technicalorganisation. Well,most of what I do is isn'tit? | spendprettymuchall my organisation, time on that. Eleanor:Or in your case,disorganisation. Gerry: Nice one.What figuredid you put down for addedvalue,by the way?Was it a negative number?
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Beatrice: At this stage,I'm not asking you to give me a detailedbreakdownof all the lT equipment we'regoingto need.lt wouldjust be usefulto havea roughidea of what'smost urgent. Dan: Sure.Well,one of the biggestproblems is the screensat the CAD stations.A lot of thoseneedreplacingwith biggerones.Roughly speaking,I'd say wellover halfof them are too small.A good two thirdsof them,actually.So, we'retalkingabout I 5 to I 8 screens,something like that. Beatrice:OK. How urgentis that? Dan: Well,I meanthey all work,they all function properly.The troubleis, the engineersspendthe vast majorityof theirtime workingwiththese screens.And becausethe detailon them is so small,it's prettyhardworkon the eyes,to the pointthat it affectsproductivity so ... Beatrice:OK. And what aboutthe big printerin here?I'veheardit's a bit of a dinosaur. Dan: Well,it is, but it worksperfectlywell,and we print nextto nothingwith it, anyway.Most of the drawingsare printedat the factory. Beatrice:Oh. Tony:With the aerodynamics thereare three develooment toolsavailableto us.The first is Fluid Dynamics. CFD software Computational With that,the testswouldobviouslybe virtual, basedon a computermodel.The secondoption is to go into a wind tunnel,witha scalemodel,or a full-sizemock-up.In eithercase,we'dprobably needto use a tunnelwith a rollingroad. Lisa: Wouldthat be necessary? Tony:Well,the thingis, the wheelsgeneratea lot of turbulencewhenthey'respinning.So to simulatethat,you needa rollingroad. Lisa: Yes,I know,but if we go for a bodywork designwherethe wheelsare mostlyenclosed, whichis likely,wouldthat be an issue? Tony:Possiblynot. lt dependshowfullyenclosed theyare. Lisa: OK. l'm just raisingthe question. Tony:Sure.lt's somethingwe can look at. The thirdoption,then,is fieldtesting,actually runningthe prototypeoutsideon a runway, or somewhere. So we can use thesetools in isolationor as a combination. The questionis, howcan we gatheras muchdata as possiblewith the limitedbudgetwe have?
Guy:Well,we needto bear in mind that the problemwith aero is that it's not just about data gathering.You also haveto validatethe data. CFD and wind tunnelsare not a hundredoercent reliable.The acid test only comeswhenyou try out a full-scaleprototypein real conditions.We needto makesurethat everythingis tried-andtestedoutside,with a full-scaletrial run. Lisa: Yeah,but let'snot forgetwe'redesigninga car that doesa hundredkilometresan hour,it's not a supersonicaircraft!The aero'snot goingto be that critical. Tony:Plus,with changeableweather,it's not easy to do back-to-back testingout in the field. Guy: No, of coursenot. I'm.iustsayingwe need to be careful...
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Arnaud: So, theoretically, the horizontalspeed will keepdecreasinguntilthe containerhits the ground.The higherthe drop altitude,the lower the horizontalsoeedat touchdown. Jenna:Sure. Arnaud: But, obviously,the higherthe altitude, the higherthe verticalspeed,up to a certain pornt. Jenna:Absolutely.So, assumingthe drop altitude'svery low the verticalspeedwon'tbe all that highon impact. Arnaud: True. Jenna:And in termsof protectingthe cargo, surelya low verticalspeed is the criticalfactor. Arnaud: I'mnot so sure it's the criticalfactor. I'd say the horizontalspeed'smore problematic. quite Because,presumably, if the groundspeed's high,there'sa dangerthe containerwill roll overand bouncealongwhenit touchesdown.In fact,if you'redroppingfrom low altitude,that's probablyinevitable. So if the containerrolledand bouncedfor 50 metres,or whatever,then you'd haveto havesome kind of destructibleexternal envelopeto protectit from the multipleimpacts. Whichwouldbe very expensive.So, arguably, rollingis the worstproblem,worsethan a high verticalimpactspeed. Jenna: Hm, you thinkso? Arnaud: So you don'tthink rolling'sa bad thing? Jenna: I'mnot convincedthe containerwould actuallyroll. Arnaud: No? Jenna: Not necessarily. The militarydrop tanks out of flyingaircraftat low level,tied to special platforms,and theyjust slidealongthe ground. And the systemsthat e.iectthingsout of the backsof planesare incrediblypowerful.So because,obviously,theyfire the containerin the oppositedirectionto the plane,that reducesthe groundspeed. Plus,they use a parachutethat whichalso helpsto slowit deployshorizontally, oown. Arnaud: Of course. Jenna: So, basedon what they do with tanks,I thinkwe can safelyassumethat we can stop a containerfrom rolling. Arnaud: But a tank'sgot massiveweight,and a low centreof gravity.With a smaller,lighter container,there'sno way of knowinghow it would behave,not withoutactuallytestingit. And even if you testedit ten times,it wouldprobably behavedlfferentlyeachtime,it wouldbe very unpredictab|e. Whereasif you drop from a hi€ h er altitude,OK, the verticalspeedis higher,but witha lowergroundspeed,it wouldbehavemore
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predictably. And that wouldmake it easierto designa cushioningsystembecauseyou'dbe dealingwith a single,predictableimpact. Jenna:Yes,but surely,a heavyverticallanding is a hugeproblem.The forceof it wouldbe far greater...
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9.3
Manfred: The first time we launchedone of got a plastic thesethings,er, we basically.iust washing-upliquidbottle,filledit about halffull ofwater,then pumpedit up with an ordinary foot pump. Interviewer:So it wasjust ordinaryhousehold stuff? Manfred: Oh, yeah,nothingtoo technical. And, actually,therewas a bit of a coincidence, becausethe openin€ in the bott|eWasjust slightlybiggerthan the fittingat the end of the pump,so therewas quite a good seal.So we pumpedit up - one of us held the bottlewhile someoneelseworkedthe pump.And we released it, and it went up, literally,like a rocket.I mean, we expectedit wouldshoot up reasonably fast,but we didn'tanticipatejust how powerful it wouldbe. lt just went Moosl, and totally exceededour expectations. So you can imagine 'l we wereabsolutely us, a groupof 2-year-olds, ecstatic.And havingsaid that,therewas one problem.Once all the waterhad come out, which happenedvirtuallyin a split-second, the bottle - becauseit was very light- startedtumbling over in the air. Interviewer:So it wouldn'tfly straight? Manfred: That'sright.But we quicklycame up with a solutionto that problem.
a
9.4
Manfred: What we did was to get a plasticcup, a strongone not a dlsposablecup,and pushed it onto the end of the bottle,at the top, to form a nose.lt didn'tgo exactlyaccordingto plan,at first.lt stabilisedit a bit, but it still wasn'tflying straight.So we tried puttingwaterin the beake( to act as ballast,and that workeda treat.With the extra inertia.and the fact that it was frontheavy,it went like an arrow.So, so, yes,we sortedthat problemout. Thenthe next goal was to increasethe power,to try and reach a higher altitude.
I9.5 Manfred: One of the thingswe did was to exoerimentwith the amountof waterinsidethe bottle.I think,initially,we expectedthat the morewaterwe put in, the more powerfulit would be. But as it turnedout, it was the opposite. What actuallyhappenedwas,if you overfilled it, therewasn'tenoughpressureto expelall the water.We reducedthe amountof waterto about a quarteror a third fu||,somethin€ |ikethat,and we also put sometape aroundthe end of the pump,to get a betterseal withthe bottle.That was reallyeffective. I thinkwe underestimated the pressurewe weregenerating.And, certainly, we were overestimatingthe strengthof the bottle. Because it got to the point where we were firingtheserocketsup to, I don't know,maybe somethinglike 20 metreshigh,somethinglike that, so you can imaginethe sort of pressure involved.And plasticbottlesare hardlyup to the job of high-pressurerocketry obviously.So, inevitably, the bottleeventuallyblew up while I was holdingit. I was rollingaroundon the groundwith sore hands,whileeveryoneelse was rollingabout laughing.So I learnedthe hardway.
94 t
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Audioscript
I9.6 Caroline:So howcredibleis this hoax theory, then? I watcheda documentaryabout it a while ago. Renato:Well,someof the questionsare quite interesting, but from what I'veread,theycan all be explained,scientifically. You know,likethe factthat the starsaren'tvisiblein the sky on the photos.Apparently,it'sjust due to sunlighton the surfaceof the moon. lt was too bright to see them,that'sall. Caroline:lsn'tthe flag supposedlywavingin the wlnd,in one of the shots? Renato:That'sright,yeah.Theysay it's because of the pole shakingafterit'd been stuckin. There'sobviouslyno air,so as a result,it kept movingfor ages,due to the factthat therewas no frictionto slowit down. Caroline: I see. Renato:Anotherthingthat'sbeenexplainedis the footprintson the surface.Peoplehad said the groundlookedwet,so it couldn'thavebeen on the moon.But, apparently, that'sthe way that type of dust behavesin a vacuum.lt sticks together,like mud. Caroline:Wasn'ttheresomeothertheoryto do with dust whenthe modulelanded,that there shouldhavebeen more dust,or something? Renato:Well,duringthe landing,therewas supposedlya lot of dust flyingup, you know, causedby the blastfrom the engines.But when the module'sactuallyseenon the surface,there's no cratervisiblebelowit. So the theoryis that, if it had reallylandedthere,it wouldhaveleft a crater.But the argumentagainstthat is that it had alreadysloweddownsubstantially by the time it reachedthe surface,and it was only gently, gravity. low descending becauseof the Caroline:So therewas only a bit of surfacedust blownuo? Renato: That's right.
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10.1
Mike: Obviously,a tubularsteeltoweronly givesyou sufficientstructuralstrengthif you give it adequateprotectionfrom corrosion- fl,e big problemwithoffthoreinstallations. So, you couldsay steelis inappropriate technically, in that environment. Loreta:They makeshipsout of it. Mike: I know,Loreta,but only becausethere's no cost-effectivealternative.But we're not talking about ships,we'retalkingaboutfixed structures. The point is, I thinkwe shouldlook more seriouslyat alternatives to all-steelsupports.And the obviousalternativeis reinforcedconcrete. Loreta:We'vealreadylookedinto it, though,and it wasn't cost-effective. Mike: Not in the shortterm.But we didn'treally look into it properlyoverthe longterm. Loreta: But you madethe pointyourself,Mike, that steel'scompletelyineffective if it's corroded. And one of the mainconstituents of reinforced concreteis steel. Mike: lt's protected,though,isn'tit? lt's embeddedinsideconcrete.That'sa muchmore effectiveprotectionthan paint. Loreta:Not necessarily. lf we'retalkingaboutthe longterm,as you say,what happensto concrete when it's exposedto the sea for a few years? lt erodes.Whichmeansthe steeleventuallygets exposed.You look at concretecoastal defences. Howoftendo you see the concreteall crumbling away,and all the steelexposed?
quality,though. Mike: That'sdue to inconsistent Youonly get that problemif there'sinsufficient cover.As long as there'sappropriate cover at designlevel,and the constructionquality's consistent,then thereshouldn'tbe a problem. Loreta:lsn't inadequatecovermoreof a problem in a slenderstructure,though?You'dprobably havelesscover,comparedwiththe big lumpsof concretethey use for coastal defences. Mike: Not if ... Hanif:Just a second. Mike: Yes,HaniP Hanif: Let'sjust thinkabout whatwe'retrying to resolve,here.The key issueis, what'sthe mostsuitablelong-termsolution?And in both cases,we'resayingsteel is necessary, eitherin an all-steeltubularstructureor in the form of reinforcement insideconcrete.But obviously exoosedsteelis unsuitablebecauseof the problemof corrosion.So the questionis, what's the most reliablewayof protectingsteel,over the longterm? And we haveto bear in mind that'just becausesomethingrequiresre€ u Iar maintenance, suchas painting,that doesn't necessarilymeanit's unreliable. As long as the maintenance is consistent. The key question is, what'sthe most economicalapproach?So paintinga steel structureevery couple of years is uneconomical only if the cost of paintingis more expensivethan the additionalcost of using concreteat the time of construction. Mike: So, to determinethe most efficient solution,we needto assessthe lifespanof a reinforcedconcretestructure.lf we knowthat,we can determinehow manytimesthe equivalent steelstructurewouldneedto be repaintedover that same oeriod.and what the cost of that wouldbe. Hanif:Yeah. Mike: But this is reallythe point I'mmaking, Hanif.We can'tcategorically say that reinforced concreteis inefficientunlesswe look into it in detail. Hanif: Of coursenot. Look,let me makea suggestion ...
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10.2
Su: With very tall structures,one of the main loadsyou needto take into consideration, clearly,is the massof the structure,its weight. Due to gravity,that mass exerts a downward load,whichhas to be transmittedto the ground. So that downwardforce means the structure is in compression, especiallynearthe bottom. Obviously,the closer you are to the bottom, the morecomoressive forcethe structureis subjectedto. But with tall structures,downward load compressing the structuralelementsis only part of the problem.Anothermajorforce actingon the structureis wind load,whichis a horizontalload,exertedby air pressureagainst one side of the structure.Becausethe structure is fixed at groundlevel,and free at the top, that generatesbendingforces.And whenelements bend,you haveopposingforces:compression at one side,tensionat the other.And at ground level,the windeffectively triesto slidethe structurealongthe ground,and the foundations belowthe groundresistthat.The resultof that is shearforcebetweenthe substÍucture and the The windgeneratestensileloads superstructure. on the foundationsof tall structuresas well, as the bendingactiontriesto pull them out of the groundon one side,a bit likea tree being uprootedby the wind.So the foundationsneed to relyon frictionwith the groundto resistthe
pull-outforce,iust as tree rootsdo. The action of the wind can also generatetorsion.Youget a twistingforcesometimes,whenthe air pressure is comparatively higheragainstone cornerof a building,althoughthat'slessof a problemwith chimneysbecauseof their circularprofile.With very largemassesof concrete,you also have to thinkabout the forcesgeneratedby thermal movement.When concreteabsorbs heat from the sun,you get expansion;as soon as the sun goes in, there'scontraction. That movementcan be significantovera largearea,especiallyas the sun generallyheatsone side of a structuremuch more than the other.So thereare all kindsof differentforcesacting on a tall structure.
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10.3
Andrej: The record speed exceededthe standard operatingspeedby a hugemargin.lt was 80o/o fasterat its peak.So you wouldimaginethat the TCV used for the record run was heavily modified.In fact, that wasn't really the case. The trainwas modifiedto a certainextentbut, just an with a fewexceptions,it was essentially ordinaryTCV.As you can see fromthis slide,one of the biggestdifferenceswas that the modified trainwas significantly shorter,in orderto make it lighter.Therewas a 500/0reductionin length, downto 100 metres.comoaredwith a 200metrestandardlength.The coachesbeingpulled were perfectlystandard - the only differences werethat some of the seatshad been removed to makewayfor all of the monitoringequipment that was carriedon board.And somechanges weremade to the bodywork,to makeit slightly moreaerodynamic, whichmeantthe drag coefficientwas reducedby I 5olo.The wheelson the modifiedtrain Weremarginallybi€ € e r than the standard size.The diameterwas increasedby | 9olo,in order to reducethe speed of revolution, to limitfrictionand centrifugalforce.And the powerof the electricmotorswas substantially higher than the standard units - boosted by 680ó' But noneof the changesWasfundamenta|. So my point is, standardhigh-speed trainscan be madeto go fasterby a considerableamount.
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10.5
Narrator: That day, Stapp was sub.iectedto When extremesof forcebeyondthe imagination. the sled's rocketsfired, he shot from zero to over 1,000 kilometresper hour in just threeseconds, him to 20 Gs. when the sled hit the sub.iecting pool of waterin the brakingzone,it was like hittinga brickwall.Stappslowedfrom the speed of a bulletto a completestop in littlemorethan a singlesecond.Incredibly, John Stappsurvived the ride,althoughso muchblood had rushedinto his eyesthat he was unableto see for sometime afterwards.Beforethe test. doctors had believed that humanbeingswereincapableof surviving forcesgreaterthan I 7 Cs. Whenthe sled hit the water,Stapp had pulleda crushing46 Cs.
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Jasmine:I thinkwhat he'ssuggestingin terms forcesis of acceleration and deceleration reasonable. Andrew:Yeah.2 C soundsabout right.Anything lessthan that,and the track length'sgoing to exceedthe size of the site. And if you start gettingcloseto 3 c, or beyondthat,thenthat's probablygoingto be a bit too muchfor the averagepassenger. for the Jasmine:I'dsay so. His calculations total distancefor accelerationand deceleration seemabout right.The problemI haveis with the lengthof the track.I think his ten-kilometre figureis OK for an idealworldscenario,but it doesn't leave much margin for error. Andrew: No. Becauseat full speed,you're going to be covering,what, a kilometreevery three seconds.So if there'ssome kind of oroblem. you'regoingto be eatingup the kilometresat a pretty frighteningrate. Jasmine:You can say that again.I think he'll neédevery ki|ometreof track |engthhe can get on that site.Plus somesort of emergency stoppin€ faciIityat the end of the |ine,just in case. Andrew: Definitely,yeah. Jasmine:Then I don't knowwhatyou think about usingwheels,insteadof skids. 10.4 I Andrew:Well,technically, it's feasibleto build Narrator: In the late I 940s and early'50s, the wheelscapableof spinningat that sort of speed, United States Air Force carried out a series of becauseit's been done on land soeed record experimentsto explore how much physicalstress cars.The only problemis, if you get a wheel the humanbody couldwithstand.A keyaim failureat the kind of speedswe'retalkingabout, was to test how much C-forcepilots were able the consequences are goingto be unthinkable. to copewith and see what wouldhappenif they Jasmine:Yeah.I haven'tcalculatedexactlywhat exceededtheir limits. Led by Air Forcedoctor centrifugalforcesthey'd haveto cope with, but John Paul Stapp, a numberof spectaculartests for wheelsof about 500 mil diameter,at full werecarriedout at EdwardsAir ForceBase in California,a locationsuitablefor the experiments speed,I workedout they'dbe spinningat over 1 3 , 0 0 0r o m . thanksto its 600-metrerail track,specially designedfor high-speedrocket tests.A rocket Andrew:Yeah,that'sa lot. Plus,of course,skids sled,capableof reachingspeedsapproaching shouldgive betterfrictionalresistanceunder the soundbarrier,was mountedon the track.On braking. topof thesled, namedSonicWind,researchers Jasmine:Possibly. fixed a seat,intendedfor an abnormallybrave Andrew: Maybe not? volunteer.Refusingto give the dangerousjob to Jasmine:Well,the frictionfrom wheelbearings a memberof his team,the man in the hot seat spinningat that sort of speedmightbe higher. was John Stapp himself.Over severalruns, Stapp And the skidswouldn'tbe in oermanentcontact was subjectedto progressivelygreater extremes withthe rails,don'tforget.But,anyway,I think of force.Each time, he resisted.Eventually,the skidsare the only safeoption. time cameto take the ultimaterisk,to surpass Andrew: I'd go for skids. Definitely. what many doctors believedto be a deadly level Jasmine:And thenfor the brakes,I thinkthe of G-force.And so on Decemberloth I 954, first pointis that,for the initialdeceleration, Stapp Wasstrapped onto soí,ic Wind Íorthe evenwithoutapplyingany brakes,the motherof all rides. aerodynamicresistanceis goingto be huge.In fact, that alone might even exceed 2 C, for a shorttime.
Andrew: Possibly.lt'd dependhow muchdrag therewas,whichobviouslydependson the bodyworkdesign,doesn'tit? Jasmine:Yeah. Andrew: I don't like the idea of a frictionsystem, againstthe rails.lt wouldhaveto withstanda tremendousamountof heat. Jasmine:Yeah.I think that'sa non-starter, at thesekindsof speeds.Aerodynamicbraking has got to be the best option.Possibly,you coulddeployflapsinitially,at top speed,then maybereleasea parachuteas a secondstage. Maybe deploythe parachuteat, I don'tknow, what sort of speeds do dragsters reach?They use parachutes, don't they?what do theydo? 400 Ks? Andrew:A bit more,I think.450, somethinglike that.There'salso the optionof reverseengine thrust,like they use on aircraft. Jasmine: In that case,though,you'dstill need anothersystem,in case you get an enginefailure. But it's a possibility.I thinkthe bottomlineis that it needsa combinationof svstemsto makeit absolutelyfail-safe.
Audioscript
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The propulsion system Will the weightof the cableallowthe baseto be movedby its own propellersor will a more powerfulsystemfor propulsionand control be required?For example,an externalpowersource.
Unit 1
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2a I navigation (monitoring)delivery vehicles 3 (findin€ ) sto|encars 4 drift 5 man overboard 6 innovativeuses of
b I uses 2 use 3a 2d 4a I
b Suggested answers Anchor system It will be oossibleto anchorthe base more securelyin shallowwater,nearthe coast.A oermanentanchorstructurecouldbe builton the oceanbed, in shallowwater.The base station couldthen be fixed securelyto it with cables.lf severalanchor structuresare built at different locationsalongthe coast,the base stationcan be moved betweenthem. Propulsionsystem Tugs(powerfulboats used for pullingships) could be used as an external oower source. However,the base station could be driven by its own propellers.The large,powerfulengines neededto propel it would be heavy,but that isn't necessarilya disadvantage,as extra mass,and thereforeextra inertia,would help to make the base more stable.
3 user's;useful 4f
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b I allows/ enables ensures 3 prevents
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allow/enable allow/enable ensure allow/enable prevent
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6a 6b on page8 Seetextin Exercise c 2i 8d 7a 3 4 6 7
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By a floating structure To attach the base to the seabed Shipswouldcarrythem Cotlisionsbetweenthe cableand space debris The anchorswouldbe raisedand the station wouldbe moved.
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reduces 6 conventional 7 reduce I ennance
8a See audioscript1.3 on page 86
9a Suggested answer The anchoring system The wind loadson the cablewill be huge.What are the implicationsfor the anchorinCsystem? The base will needto be movedcontinuallyand sometimesurgently.what temporarysystem couldbe usedto hold the base in position? Shouldthe base be in shallowwaternearthe coast, or in deep water further ofEhore? The choicewill havean impacton the designof the anchorsystem.
t
3b
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11a It's a flat belt for liftingelevatoB which is used instead of a cable. Comparedwith cables,the Cen2 systemhas a numberof advantages.
c The notesare missingarticles(a/an,the)and some auxiliaryverbs [e.9.be).
b I 2 3 4
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A technicaladvantageis a type of technology that is superiorin someway - for example, more efficient,more powerfulor more reliable - comparedwith a related type of technology - for example,a competingproduct [onesold by anothercompany)- or comparedwith an earlier model of the same product.
enhanced reduced eliminated
2b
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dramatically 6 7 entirely I extremely considerably
5c
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conventional superior eliminates
c Richardsuggestsusingeverydaylanguage to avoidexplanationsnot beingunderstood; usingsomejargonand then explainingit using everydaylanguageto avoidsoundingpatronising; explainingdifficultconceptsby comparing technicalpoints with things in everydaylife to illustratethem;and usingsome humour to avoidsoundingdull. 15b 2 A columngoingdowninto the ground 3 To drill 4 ConcreteDouredon the constructionsite in its final oosition 5 Made at a factory,away from the site 6 To hammerin 7 Likea giant hammer I Likea giantdrill 9 A kind of claysuspension/ a sort of mud d I 2 3 4
put simply;in otherwords;basically effectively;essentially;basically what we call: what we refer to as if you imagine;if you picture
16 Suggested answers endThereare two typesof pile foundation; bearingpilesand frictionpiles.Essentially, end-bearingpilesare usedwhenyou havesoft groundwhichis on top of hard€ r ound or rock. Basically,the pilesgo throughthe soft ground and sit on the hardgroundbelow.lt's a bit like buildingover water.The soft ground is like water, whichcan'tsupportanything,and the hard groundbelowit is like the seabed.Put simply, the pilesare like stilts.Frictionpilesare different. They'reusedwhenthere'sno hardground.In simpleterms,the sidesof the pile grip the soft groundaroundthem.lf you picturea nail in a pieceof wood,it's the same thing.The nail is grippedby the woodaroundit. Sometimesthe bottomsof frictionpi|esare madeWider.|ma€ i ne a leg with a foot at the bottom, it's the same principle.
I conventional superior
4d highly exceptionally significantly
entirely;totally dramatically considerably; highly exceptionally;
14a I That you shouldn'tusejargonor it will sound like nonsenseand that technicalconceptscan be difficultto explain,evenusingeveryday language. 2 Explanationsthat are boring. 5 Speakingto an adultas if you'retalkingto a child.
Unit 2
2a 2 Class 3 Copper 4 Aluminium b 2a 'Ie c 2 3 4 5
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The main pointthat lrina makesis that it's imoortantto considerthe total environmental impactof a product,includingproducingit (preand recyclingit (post-use). use),usingit (in-use) light She givesthe exampleof an energy-saving bulb.
Answer key
I
C Soohiaand Pete'sideas: Pre-use:aluminiumproduction[extraction from ore and recycling), coatingsteel (galvanising), transportingand handlingbulk material,cutting and welding In-use:weight(impacton fuelconsumption), lifespan(frequency of manufacturing) d Suggested answers Electricalwiresin vehicles For pre-use,as far as I know it takes more energyto producealuminiumthan to produce copper,if it's derived from ore. However,it takes less energyto transportaluminium,becauseit's lighter. For in-use,I'msurealuminiumis betterbecause it's lighter,so the vehiclewouldconsumeless fuel. For post-use,both aluminiumand coppercan be recycled'|'dsay it takes|essener€ y to hand|e and transportaluminium,becauseit's lighter. Externalwallsin houses For pre-use,it takes a lot of energyto produce bricksbecausethey haveto be fired in a kiln. They'realso heavyto transport.Softwoodis lighterto transport,and I'dsay it probablytakes lessenergyto saw it and handleit, compared with makingbricks.Duringconstruction, building with bricks uses more energy,as sand and cementhaveto be transportedand mixedto make mortar. For in-use.wood is a betterinsulatorthan brick whichis an advantage,as the houseshouldtake less energyto heat. In theory,softwoodcould last as long as bricks,if it's properlymaintained. But in oractice.that will oftennot be the case. So, constructionenergycouldsometimesbe higherfor softwood,as housesneedto be rebuilt moreoften. For post-use,it's possible to recoverboth bricks and softwoodfor re-use,but neither is very easy to recycle. 4 Suggested answers I Brakesare designedto slowdownvehicles or movingparts.Oftentheywork through friction,by app|yin€ pressureto padsWhich are pressedagainstthe sidesof a disc,the insideof a drum,or directlyagainsta wheel rim.Alternativesincludesystemsthat use electromagnetic force,systemsthat exploit the brakingeffectsof enginesor flywheels (viaclutchesand gearboxes), aerodynamic brakingsystems(forexamplespoilerson aircraft,parachuteson dragsters),and reversethrusterson jet engines.Brake discs are oftenmadeof ferrousmetals(iron-based - for examplesteel),or sometimesceramic materials. 2 Examplesof materialsusedto make pads include:comooundsof advancedmaterials (cars),ferrousmetals(trains),rubber (bicycles), ceramics(performance cars). 5a Creen refersto ecologicalissues.Red refersto heat (redhot means very hot). Also, a hot topic is a currentimportanttopic. b I 2 3
Becausethey use friction,whichwastes energyas heat They recoverheat and use it to powerthe car. The abilityto generatehighlevelsof friction, and to resist the effectsof friction and conseouentheat
4
Heat fromthe enginebeingabsorbedby the chassis,whichcan damagesensitiveparts suchas electroniccomponentsand plastic parts
c 29
5b
4f
5d
6a
6c I c
2b
3d
4a
5e
7e
e
I 2
b;c d;e
4 5
e a;b;c
d
8c 2 abrasionresistance 3 thermalstability 4 durable lightweight 9a lc
2e
b 1 tyres 2 drivebelts 3 brake pads
5b 4 5
5d
bullet-resistantarmour sealinggaskets
10a I At the dentist's 2 The tool is a dentaldrill. 3 Titaniumcan be usedfor the handle,and tungsten-carbide and diamondfor the bur. l 2
c lb
t2
Ii€ h tweight abrasionresistance 2a
3e
t4a I Watchmaterialsare sometimeschosenfor marketingreasons,not technicalreasons. 2 Theyconsideredusingsubmarine-grade steel in some modelseventhoughwaterresistance actuallydependson the jointsand seals,not the metalused. materialsare 3 Many good watch-making eitherordinaryor complex,and so are not very marketable. 4 Consumersare not technicalexperts,and makechoicesbasedon their imoressions. ratherthan on factualinformation.
b 4a
c Suggested answers In tyres,punctureand tear resistancehelpto stop puncturesand blowoutsand abrasion resistancehelpsthe tyre to last longer.In drive belts,highelasticityallowsbeltsto fit tightly and abrasionresistancehelosthem resistthe frictioncausedby the belt turning.In brake pads, abrasionresistancehelpsthe pads to last longer and thermalstabilityhelpsthem resistthe heat generatedduringbraking.Kevlar@ helpsmake armour,whichis generallyheavy, bullet-resistant whichis betterfor the vehicle's more lightweight, performance.Kevlaromakes sealing gaskets durableand its thermalstabilityallowsthem to reslstheat- for example,in enginecylinder heads- and its chemicalstabilitymeansgaskets are not affectedby enginefluidssuch as fuel, lubricatingoil and coolantliquids.
b
13a I corrosion resistance 2 water resistance 3 scratchresistance 4 shock resistance
5 4 4c
durable thermalstability 5d
Suggested answers I Examplesof situationsusedin advertising includemotorracing,watersportssuchas surfingand diving,and aviation. 2 The intendedmessageis that watchesare accurateand are resistant. 3 Higherqualitywatcheskeepgood time; are resistantto waterand shocks;and are madefrom moreexpensive,better-looking materlals. 4 Describingsomethingas water-resistant suggestsit can resistwaterup to a certain limit,for exampleto a certaindepth or pressure.Describlngsomethingas waterproofsuggestsit givesunlimited orotectionfrom water.
I
3 q
6 7 8
T T F - it needsa protectivecoating. F - he says it's fairlypoor in terms of looks. F - no - for the reasonsgiven above. F - inadequatematerialshaveneverbeen chosenfor marketingreasons. T F - complicatednamesare not good for marketing.
c 2 3 4 5 6
exceptionallyresistant not at all suitable treoctdously marketable Ielativelycomplex not all that good
d I 2 3 4 5
extremely,exceptionally, tremendously qulte,fairly,pretty,relatively not very,not particularly, not (all)that not enough,insufficiently, not adequately definitelynot, not at all
15 Suggested answers Steelis relativelyheavyand very tough.lt is pretty scratch-resistantand shock-resistant. Mild steel is not very corrosion-resistant but stainlesssteel has good corrosionresistance and is thereforesuitablefor watches.Class is quite heavyand is water-resistant and corrosionresistant.Ordinaryglass is very brittleand has fairlypoor shockresistanceand scratch resistance, althoughit is still suitablefor watches, glass is more durable.Aluminiumis Toughened relativelylightweight and is fairlytough.lt has good corrosion resistance.lt is thereforesuitable for watches.Titaniumis exceptionally lightweight and toughand has excellentabrasionresistance. It is also extremelycorrosion-resistant and is thereforean excellentwatchmaterial.Gold is extremelyheavyand prettytough,although softergradesof gold havequite poor shock resistanceand scratchresistance. Gold has excellentcorrosionresistance. lt is suitablefor more exoensive.decorativewatches.
I
Unit 3
2a The aim of the projectis to formulatea policythat will statewhichplugand socket configurationstheir companyrecommends, and explainthe technicalreasonswhytheyare recommended.
Answerkey
97
b Ihe profile of the pins means the shape of the individualpins,for examplea rectangularcrosssectionor a clrcularcross-section. means a uniform A standard configuroúlon arrangement, for examplein a givencountryall plugshavea standardlayout- they all exactly the same. c a6
b4
r3 d 2 5 4
cl
rounded 5 rectangular 6 cylindrical
d5
e2
linear triangular
e triangle;triangular; rcctangle;rectiangular; lylinder; cylildrical; line;!!ear
3a
Pictureb b 2 5
ridges;grooves;recessed;flush with; set back oins
4a '|
2
Advantages: The plug resistspulloutforces. Nothingcan touchthe pins if the plug is partiallypulledout. Disadvantages; lt's difficultto pull out. Advantages: Childrencan'tstickthingsin the socket. Disadvantages: lfthe mechanismis too sensitive,it can be difficultto insertthe plug.
5 See audioscript3.6 on page88 6a I T F - castingis a differentdiscipline 3 F - it's a slangterm F - work involvingabrasivesis noisier 5 T 6 T
b I 2 3
Sawing Shearing Drilling
4 5
Milling Flame-cutting
c 2 3 4
guillotine 5 kerf 6 toothed blade
abrasivewheel hole-saw
7a secondar| operafions:additional machining, suchas polishing net-shapedports: parts with accuratelycut edges;often intricate shapes heat-affectedzone: the area modified by high temperatures(resultingfrom the heat of cutting) mechonical stresses:physicalforces such as shearforceswhensawingor guillotiningmetal narrow kerf: narrow thicknessof material removedduring cutting;especiallyeasy to do with waterjetcuttinc tightlAnested:when severalcomponentsare cut from the same piece of material the components can be placedclosetogether,makingbetteruse of the material. b I 2 3 4
net-shapedparts heat-affectedzone mechanicalstresses narrow kerf
98
Answerkey
c I
3
4
especiallygood when uselesswhen not the best solution ideal for
I Suggested answers Drillingwith a bit is good for cuttingblind holes. Drillingwith a hole-sawis idealfor cutting timber. Flame-cuttingis perfectfor cutting metals.lt's uselessfor cutting ceramics. Crinding is perfectfor cuttingwide kerts.lt's totallyunsuitableif you don'twanta heataffectedzone. Cuillotiningis especiallygood for cuttingthin materials.lt's not particularlysuitablefor cutting thick materials. Milling is especiallygood for cutting metals.lt's totallyunsuitablefor cuttingtimber. Punchingis suitablefor cuttingthroughholes.lt's uselessfor cutting blind holes. sawing is idea|for cutting strai€ h t edges.|t'snot so good if you need to cut curved edges. Water jet cutting is ideal if you need curved edges. lt's not so good for cuttingvery thick materials. 9 See audioscript3.8 on page88 10a I To involvetheirsuppliersmoreactivelyin design 2 Doinga lot of workfor no returnand covenngcosts 3 They want to work with fewersuppliers,so there would be more work. b I 2
c
I 2 3
Mechanicalfixings:screw,rivet,clip fixings:weld,adhesive Non-mechanical weld bolt adhesive
4 5
screw rivet
d I .ioining; fixing 2 bolting;riveting 3 bonding;welding;gluing 1la I together 2 eachother 3on 4 to/onto
b I
on
2 each other 3 together c
I
3
4 5
onto/to to
Main advantage:They can be removedeasily. Theycan work loose. Main disadvantage: It can't be removedeasily. tightened. Fixingscan be inadequately Adhesivescan be usedon improperly preparedsurfaces.Welds can be flawed.
tza
Suggested answers I In early aircraft,timber frameswerejoined togetherwith adhesive/ glued together,or screws/ screwedtogether. 2 Injet aircraft,alloy body panelsare joined togetherwith rivets / rivetedtogether. 3 In aircraftcabins,the seats are fixed to the floor with bolts / bolted to the floor.
In aircraft cockpits, the windshield is bonded to the fuselage with adhesive / glued to the fuselage.
13a
See article on page 28
b a2
b3
c4
d I
c a
The balloonsclimbedfasterthan expected, then entered controlledairspaceadjacentto an airport. b A ropetan€ | ed Witha power|ine,then Mr Walterswas arrested. c The modernequivalent,clusterballooning, is not a mainstreamsport,but is becoming more popurar. Weather d A € a rden chair,he|ium-fi||ed balloonsand ropes !4a a over b below;beneath;underneath c alongsideiadjacentto; beside d around e outside f inside;within b I above 2 around 5in c 2 3 4
inserted situated suspended
4 5
within beneath
5 6 7
located projecting positioned
d located;situated 15a See audioscript3.9 on page88 b '|
lt's prettytime-consuming to assemble. Cable ties are fastenedaround the bottoms of the balloons,to fix them to the ropes. 3 The balloons are attachedto ropes of differentlengths,which are attachedin groups to straps, like the branchesof a tree. 4 Wateris carriedin bags,as ballast.Tapson the bags are used to releasewater. 5 The balloonscan be releasedone by one. 6 The balloonscan'tbe releasedone by one. 2
c Suggested answers The heliumcouldbe containedwithina smaller numberof largerballoons.The balloonscould be made of stronger materialthan weather balloons,and couldbe permanentlyfastenedto the ropesor straps.This wouldmakethe balloon cluster faster to put togetherand inflate.Twoor threeof the balloonscouldhavevalves,allowing heliumto be releasedduringthe flight.This wouldalso allowthe balloonsto be deflatedafter the flight,so that theycouldbe reused.
I
Unit 4
1 For the designof a largecruiseship,several hundreddrawingswouldneedto be produced. Thesewouldincludegeneralarrangement drawings,suchas plansof the overalllayoutof eachdeck,elevationsof the sidesof the ship, and cross-sectionsthroughthe ship at different points. Notes on these general arrangement drawingswould then refer to more detailed drawingsof assemblydetails.As well as being
I generalarrangement dividedinto small-scale drawingsand larger-scale details,the drawings would also be organisedinto different specialisations, suchas structure,electrical powercircuits,lightingcircuits,watersupply,air conditioning, lifts,fire sprinklersystems,engine installations, etc. 2a I Part of a staircase(Staircase3, Deck C) 2 The numberof panels,and their size b 2 3 4 5 6 7
elevation explodedview cross-section schematic note specification
c generalarrangement: plan,elevation detail:explodedvieWcross-section d I 2 3
4 elevation cross-section 5 plan
schematic explodedview
3a The scaleis the ratio betweenthe sizeof items shownon a drawing,and theiractualsize(in reality).A scalerule has severalscales,allowing dimensionsto be measuredon a drawing,to determinethe actualsize. b I 2
The widthof the panelat the top. That you shouldn'tscaleoff drawings. It'smentionedbecausePavelsuggests measuringthe dimensionon the drawings with a scalerule to find out the actual dimensions.
c I ls this drowing to sco/e? : Do the
dimensionscorrespondwith a scale?
2 It's one to five' = Íhe dimensionson the J
drawingare I /5 of their real size. ... goushouldn'tscoleoffdrowings...= You shouldn'tmeasuredimensionson a drawing usinga scalerule and take them to be exact. ... it's octuol size, on a full-scaledrawing ... : The dimensionson the drawingare the same as their real size.
4 Typesof drawingrequired:a plan showing the perimeterof the handrail(possiblescale I :I 00);an elevationof a short lengthof the handrail(possiblescale 1:I 0);a sectionof the handrail(possiblescale I :| 0);detailsshowing key connections,such as those betweenhandrail postsand deck,and top rail and posts(possible type of steel, scale- actualsize).Specification: types of weldedjoint, types of bolt, type and other materialssuchas colourof painucoating, plasticsurroundto top rail 6a The wordsmeanhow exactsomethingis, for examplehowcloselythe sizesof manufactured itemsmatchtheir designedsize.
b
A suoerFlatfloor has a much flatter surface. It'sfinishedmore preciselythan an ordinary concretefloor. 2 Ordinaryslabscan be flat to +/- 5mm. Suoerflatslabs can be flat to within I mm. 3 Slightvariationsin floor levelcan cause forkliftsto tilt, causingthe forksto hit racks or drop items. I
c
Toleranceis the acceptabledifferencebetween idealdesignedsizeand actualsize.In machining and assemblyprocesses,it is impossibleto achieveentirelyprecisesizes.A degreeof toleranceis alwaysrequired. d I 2 3 4
within p l u s ;m i n u s tight outside
e I 2 3 4
outsidetolerance +/- 0.5mm withintolerance tighttolerance
f Differencein meaning:Plus or minus I mm meansthe sizemayvary by a maximumof I mm eitherside of the 'ideal'dimension.As an examDle.if the diameterof a steel bar is s p e c i f i e ad s 1 0 0 m m + / - | m m ,t h e d i a m e t e r may be a maximumof l0l mm at its widest pointand 99 mm at its narrowestpoint.Since the totalvariationcan be I mm eitherside of the '100 m m ' i d e a l ' ( b e t w e e9n9 m m a n d l 0 l m m ) , the maximumtotalvariationbetweenthe widest and narrowestpointsis 2 mm. However,no point must be furtherthan I mm eitherside of the 'ideal'size. Within I mm describesonly the totalvariationin size.This meansthe size mayvary by a maximum of I mm abovethe idealdimension(as longas no point is belowthe idealdimension)or it may vary by a maximumof I mm belowthe ideal dimension(as longas no point is abovethe ideal Therefore, a minimumdiameterof dimension). 1 0 0 a n d a m a x i m u mo f l 0 l w o u l db e w i t h i nI m m ,a s w o u l da m i n i m u mo f 9 9 a n d a m a x i m u m o f 1 0 0 ,a n d a m i n i m u mo f 9 9 . 5 a n d a m a x i m u m of 100.5. Examplesof uses:lt is usualto specify+/ toleranceswherea specificidealsize is critical, for examplethe sizeof a holefor a bolt. ln this case, if the ho|eis too narrow Ítoofar be|owthe idealsize)the bolt will not fit into it. lf the hole is too wide (toofar abovethe ideal size),the bolt will not fit tightlyenough.'Within'is oftenused when specifyingtolerancesfor concretefloor surfaces.In this case,the importantissueis the totalamountof variationbetweenthe highest and lowestooints on the surfaceof the floor (whichdetermineshowsmooththe floor is). 7a I A superflatfinishfor the entirefloor 2 Free movementfloors are superflat everywhere.On defined movementfloors, only specificlanesare superflat. 3 Long,narrowlanesallowa higher-quality finishto be achieved. 4 This can be done at a later stage to make other partsof the floorsuperflat. 5 lt can be positioneddeeperin the concrete.
b I long 2 wide 3 height c J
width length depth
4 5
5
thick depth
thickness height
d diameter:the maximumwidthof a circle radius:the distancefrom the centreof a circle to its circumference(halfthe diameter)
8 The capitalT refersto the thicknessof the flanges. The small t refersto the thicknessof the web.The capitalW refersto the width ofthe flanges.The smallw refersto halfthe widthof the columnfrom the centreof the web to the edges of the flanges. The small r refersto the radius ofthe curve at the joint betweenthe web and the flanges.The capital D refersto the total depth of the column,from the top of one flangeto the bottom of the opposite flange.The small d refersto the depth of the web, measuredbetlveenthe ends of the curvesat the joints,at the pointwherethe curvesare flushwith the face of the web. 9 A designprocessis the developmentof a design. A typicaldesignstartswith a designbrief,which statesthe designobiectives.Initialideasare then put togetheras roughsketches.Theseare then developedinto preliminarydrawings,which are more detailed and are often drawn to scale. The preliminarydrawingsare then developed, incorporating commentsfrom differentmembers of the designteam,consultantsand the client. Once the designhas been sufticiently developed, workingdrawingsare produced.Theseare then usedfor manufacturing/assembly/construction. Frequently, workingdrawingsare revised (changed) duringthis latterphase,in orderto resolvetechnicalproblemsencounteredduring manufacturing/assembly/construction. 10a I designinformation[atdifferentstagesof the design process) 2 sketches,design brief, revised/amended drawing,supersededdrawing,preliminary drawing,workingdrawing,summary/notes b I b
2d
3c
4a
5e
C I
sketch
3 4
working drawing preliminarydrawing
d 2 3 4 5
revise rough issue commenton
6 7 8
supersede specify resolve
2 designbrief
e Suggested answers I The drawingneedsto be amended/revised. 2 The designneedsto be sent to the clientfor commentsand approval. The site engineerneedsto be contactedto checkwhichrevisionof the drawingthey nave. 4 The three differentcontractorsneed to be issuedwith the revision. E Roughsketchesneedto be done first and the clientto commenton them. 11b I b d '|
2a
3c
The seniorengineerwill decidewhetheror not the team needsfurtherrevisionsof a drawing. lf the drawing is needed, the team will receive copies of all further revisions. lf not, no further revisions will be issued to the leam. S/he will liaise beBveen the mechanical and electrical teams, and will report to the proiect manager. All three design teams will be located in a single open-plan office.
Answerkey
99
e Suggested answers I First,the preliminarydrawingwill be circulatedto all the seniorengineers.The engineerswill decidewhetheror not the drawingis requiredby their team.lf not,they will say it isn't requiredand afterthat, no more revisionsof the drawingwill be issued to them.lf the drawingis required,they'll say it's needed.They mightcommenton the drawingand requestamendmentsor approve it. Theywill also receiveall furtherrevisions of the drawing,includingworkingdrawings. 2 The mechanicaland electricalteamswill be able to work on the preliminarydesign togethereasily,thanksto the open-plan office.As the drawingsare developedthey'll be able to discussamendmentsin the same way. 3 The mechanicaland structuralteamswill be able to work togetherto solvethe problemin the open-planofficeand reviseddrawingswill be produced.Thesewill then be approved by both the mechanicaland structural teams.Reviseddrawingswill be issuedand circulatedto all thosewho needthem. 12 Often conflicting(different) informationis shown on differentdrawin€ s . on one drawing,the dimensionsof a componentmay not correspond with thoseshownon a relateddrawing.Clashes are anothercommonproblem- different drawingsmay showdifferentcomponentsin the same positionwithinan assembly,meaningthe assembIyWi||not fit togetheras desi€ n ed. Key dimensionsand assemblydetailsmay also be missingfrom the set of drawings,leavingthe productionwith inadequateinformation. 13a I Designproblemsand solutions 2 A queryis a question.An instructionis an explanationof what to do / officialpermission to do somethin€ . 3 Writtenfollow-upis importantin order to keepa recordfor contractual/financial purposes.
b 2 869 5 869;870 c
I 2 3
clash request propose
4 5
867;868 867;868;869
4 5
advise clarify
14a See audioscript4.6 on page 89 b 2 3 4 5
c|ariÚ contradicts clash propose
6 7 I
alternative as per confirm
d Suggested answers As discussedtoday,I confirmthat the connection betweenthe plateand T sectionon the ski lift shouldhavesix bolts,not eightas shownon the detail.The two bolts shownon the detailwhich wouldclashwith the flangeof the T sectionare not reouired.
100
I
Answerkey
I t
Unit 5
See audioscript5. I on page89 2a I To finishfirst,firstyou mustfinish 2 Engineering enemies 3 Wearand tear
b
I 2 5
heat pressure vibratlon
4 5
shocks abrasion
c Suggested answers '| shocks 2 heat 3 abrasion 4 shocks 5 abrasion 6 abrasion 7 shocks I pressure(causedby heat) 9 vibration
3a I
3 4 6
b
T F - the driverswltchedthe engineoff T T F - the wheelnut wouldn'tturn F - the driverdidn'tbendthe suspension
I 2
blocking jam
3
bend;snap cracK
C I 2 3
leakingout r u no u t cut out
4 5 6
clog up wearingout blow up
d See audioscript5.2 on page89 e 2 3 4 5
leakingout jammed cloggedup worked loose
6 7 I 9
blocked(up) bent wornout run out
4 Monza has longstraightsand severalchicanes. This meanscars are at full-throttle for longer, and needto do a lot of heavybraking.Problems: Enginescan overheatand blow up; brakes can overheat;ridingthe kerbscan causethe suspensionto crack,bend or snap;the righthand cornerscausethe tyreson the leftof the car to wearout fasterthan thoseon the right side:and leavescan block up the radiators. 5b User'sobseNations= whatthe personusingthe machinehas noticed Natureof fault - type of problem Circumstances of fault = in whattype of situationthe faulthappened/happens Externalfactors- thingsfrom outside,for examplethe weatheror somethinghittingthe machine Processof elimination- thinkingof possible problemsand decidingwhichare not possiblein orderto reducethe numberof oossibilities ldentifythe fault - find the fault/ decidewhat the faultis Determineactionand urgency= decidewhat to do about the problemand decidehowquicklyit needsto be done
6a 1 Checkinjection 2 Water in the fuel system 3 Becausethe fuelwas put in directlyfrom a
deliverytanker Whenthe engineis startedfrom cold A faultyfuel pre-heaterplug The plugcan be changedat the next service. It'snot an urgentproblem.
4 5 6
b
I 2 3 4
defect defective;faulty major minor
c I b
2c
5 6 7
propeny intermittently systematically
5a
d Suggested answers '| This is an intermittentproblem.lt's probably causedby wearand tear. 2 This was a suddenproblem.lt's probablya faultypart,or an installationproblem. 3 This is a systematicproblem.lt's probablya faultypart,or an installationproblem. e 2 3 4 5
lt soundslike it's lt couldbe / lt mightbe | doubt it's lt can'tbe
f 2 5 4
it mightbe it mightbe it can'tbe
5 6
| doubt it's lt soundslike it's
7a minor;systematic b Suggested answers It can'tbe waterin the fuel supply.ghis would causemisfiring.) It couldbe a cloggedfuel filter.flhe engineis performingconsistently, but is downon power.) I doubt it's a compressionleak.[fhis would probablyresultin increasedfuel consumption, and wouldprobablycausemore major problems.) It can'tbe a lubricationproblem.flhis would causeoverheating.) I doubt it's a blockagein the exhaustsystem. fl'hiswouldcausemore majorproblems.) 8 checklists= listsof thingsto be checked standardprocedures= specific,plannedwaysof dealingwith situationsand problems back-upinstallations= secondary/additional equipmentthat will work if main equipmentfails plannedmaintenance- replacingpartsat plannedtimesevenif they are not wornout 9a I An incorrect(oversized) hydraulicpipe was fittedto the right-handengine. 2 The pipe rubbedagainsta fuel line. 3 The fuel line ruptured,resultingin a major leak.
b 04:58b 06:27 c c 2 5 4 5 6
05:36d
oversized 7 inadequate 8 undetected 9 abnormal l0 insufficient I I
0 6 : 1 3a
disproportionate irregular imbalance malfunction inoperable
d I 3 4 5 6 7 I
incorrecVabnormal inadequate/insufficient irregular oversized malfunction imbalance undetected inoperable
10a IF
- the tyre pressuresare well down
2T 3 F _ on|yone € r oup of tyresis |ow 4r b
13a '|
2 3 4 5
The levelis OK. The coolantis fullof residue/ black. lt looksreasonable. OK, thereare no signsofdamage. This will needto be lookedat.
b They'reworkingon an industrialmachineas theirdecisionnot to changethe filterwouldbe in aircraftmaintenance. unacceptable c Drainthe coolant.Removethe filter,examineit and cleanit. Put the filterback in. Replacethe coolant.Adjustthe bladesand tightenthem.
6
In terms of / As regards/ With regard to / Concerning/ Regardingthe materials,what is the bodywork made or., In terms of / As regards/ With regard to / Concerning/ Regardingthe schedule,when will the work start? In terms of / As regards/ With regard to / Concerning/ Regardingthe power,what will the maximumoutputneedto be? In terms of / As regards/ With regard to / Concerning/ Regardingthe heat resistance, what sort of temperaturewill the paint need to withstand? In terms of / As regards/ With regard to / Concerning/ Regardingthe tolerance,what levelof precisiondo you want us to work to?
t4a 3a A f o r k l i fttr u c kh i t a m a c h i n eu n i tl P S l 5 a n d I Can be variedconsiderably madea hole in the main oanel.The technician 2 Physicalbut not so extremethat peopledon't at the factorylookedat the machine[hedid not 4 watchgraphics open it up or look inside)and reportedthat the 3 Best to try out effectsin practice as it's c bladealignmentmechanismwas damagedand difficultto do in theory ln general,insufficient tyre pressurescouldbe that liquidlubricantwas leakingfrom the unit. Therewas also an electricalcracklingsound causedby: pressureloss overtime (alltyres b lose air pressureprogressivelyover a period of causedby earthing/short-circuiting) I how much [presumably severalmonths)due to inadequatemaintenance; whenthe machinewas switchedon. 2 the amount a slowpuncturelair leakingslowlyfroma small 5 calculate/give a quantity b hole in the tyre);air leakingfroma valvedue to judge/decide 4 Dismantle the lsolate the electrical supply. a problemwith the valve,for exampledirt in the 5 measure/test externaloanels.Drainthe lubricant.Checkfor valvepreventingit from closingproperly;a faulty partsand c pressuregauge on the compressorused to inflate internaldamage.Removedamaged replacethem.Add lubricant.Adjustthe blades. 2 the degreeto which the tyres,givlngan incorrectpressurereading. Put on the externaloanels.Reconnectthe 3 Towhat extent With this specificproblem,perhapstherewas electricalsupply.Testthe machine. 4 to whatextent/ the degreeto which a faultwith the compressorusedto inflatethat 5 To what extent block of tyres - a differentcompressorto the 6 quantiíy/determine I Unit 6 one usedto inflatethe otherblocks- and this 7 assess gavethe maintenance technicianan incorrect 1 pressurereadingwheninflatingthat blockof 6a Needsanalysis(alsocalledrequirement tyres.lt's unlikelythat a technicalproblemwith I It'sbeingcarvedfrom a blockof sandstone. analysis/ gap analysis)is findingout what the the tyres,such as slowpuncturesor leaking He's overseeingthe logisticsof the project. requirements are for a newprojectby looking valves,wouldoccuron severaltyresat the same On a stoneplinth at all the factorsthat are involvedand howthey time and causeexactlythe same loss in pressure will interact. Howto stop the slingsfromgetting acrossall the tvres. trappedbeneaththe statue,so they can be Budget = how muchmoneyis available,for withdrawn,afterthe statuehas been lowered examp|ethe budgetfor designing,bui|din€ and 11a onto the plinthby crane testing a prototypefor a new high-speedtrain Suggested answers Capacity how muchsomethingneedsto Repairsare done to correcttechnicalproblems b produceor carry,for example how much power after breakdownshave occurred drill= cutahole an electricalcircuitmust be able to carry Maintenanceis done to preventtechnical horlzontal = level Dimensions= size.for examolethe diameterof problemsfrom occurring. bar = a long pieceof metalwith a circular the wheelsof a mountainbike section broken = repait for examplea boltthat has = Layout the overallshapeof somethingand vertical= at 90 degreesto the ground broken the positionsof differentparts relativeto one = liftingeyes - metalringsthat hookscan be fixed clogged repair,for examplea filterthat is another,for examplethe layoutof the main to for lifting completelycloggedand has causeda technical componentsof a car engine. problem,or maintenanceit is slightlyclogged resin = a type of strong adhesive Looks = what somethinglookslike from an a grab = mechanicaliaws that grip objectsto and is ready to be replaced aestheticpointof view for examplethe look of a lift them defective = repair,for example a part that was car in terms of the shape of its bodywork friction = resistanceto sliding when two surfaces incorrectlymanufactured and did not work Performance= similar to capacity,for example = are pressedtogether faulty 1sp3;.for examplea sensorthat is how much power a generatorneeds to produce givingincorrectmeasurements Regulations: lawsand standardsthat a design c = worn maintenance, for exampleworntyres mustcomplywith,for examplesafetyregulations I Drill into the sidesof the statueand insert needto be reolaced and qualitystandards horizontalbars,whichcould be usedfor Timescale= howmuchtime is available,for lifting. b examplethe schedulefor buildinga newairport Drill into the too of the statueand insert Suggested answers partsand fluidsare replacedon verticalbars with liftingeyes,set into the Similarities: 2 a stonewith resin. a plannedmaintenanceprogramme,partsare I capacity 3 timescale Use a grab on the end ofthe cranejib,to lift checkedvisuallyfor wearand damage,and that 2 graphics the statue by friction. they are tightlyfixed,correctlyaligned/balanced, I & 2 are rejectedbecause holes can't be etc. b drilledinto the statue[evenif they werefilled Main difference: standards in aviation are more 4 as regards I regard rigorous afterwards,they would be seen). 2 terms 5 regarding 3 is rejectedbecausethe statue is too heavy 3 concerned tZa and wide. 2d 3c 4a 5C 6b c 7j 8e th l0i d I In terms of / As regards/ With regardto / couldn't 5 about Concerning/ Regardingthe dimensions, what b 3 could 6 another is the overallsizeof the module? 2d 4c 3j 5c 6b alternatively 7 don't 7i l0e 8a th I
abnormal/incorrect insufticienVinadequate disproportionate proportionate
Answerkey
101
7b The stonemasons' suggestion Use blocksof ice.The blockswouldact as temporaryspacers betweenthe statue and the plinth,to allowthe slingsto be withdrawn,and Wou|dthen melt,a||owin€the statueto sit down on the plinth. Potentialproblem l: Outdoortemperatures be|owfreezin€ Wouldpreventthe ice from melting.Solution:In this case,blowtorchesor salt couldbe usedto melt it. Potentialproblem2: Very hot weatherwould causethe ice to melt quickly.Solution:To compensatefor this,largerblocksof ice could simplybe used. 8a Feasibilita means the possláilita of doing something. 9a I For the boltsthat will be usedto fix the beamsto the wall 2 Core drilledholesare formedafterthe concretewallshavebeen cast,usinga diamonddrill. Preformedholesare formedby puttingplastictubes into the wallswhilethe concreteis beingpoured. 3 Spacearoundthe bolts,in the holes,to allow their position to be ad.iusted 4 Positioningthe holespreciselyor theywon't matchwith the beams 5 Time and cost b See audioscript6.5 on page 9l d I
The plastictubesare cheapto buy and quick to put in. lt's slow. Within20mm Wthin lomm Thatthey'renot positionedaccurately The tolerance
2 3 4 5 6 e 2 3 4 5 6 7 8 9 '10 e '|
peanutsO painstakingO perfectlyO stretchingO wayo borderlineO tallO forever6 l e g6
o
20
t2a Suggested answers cables/connections: lmprovethe user interfaceby makingcableseasierto connectand disconnect; reduceenvironmental impactby makingcables onlyfrom recyclablematerials. case: lmproveaestheticsby offeringa range of colours;make manufacturing easierby making the casefrom a smallernumberof components. inldtonercartridges:lmprovethe user interface by makingcartridgeseasierto removeand replace;consumables- makecartridgesbigger so they last longerand needto be replacedless often. pape!:lmprovereliabilityby refiningmechanisms to help preventpaper blockages;improveoutput speed by making the paper flow faster. powe-r:Reduceenvironmentalimpact by having whennot in the printerswitchoff automatically use. software:lmprovethe user interfaceby making the softwareeasier to use.
c I
30
4@
10
I
11 Suggested answers Betterqualitymaterials,for examplemakinga tool from stainlesssteel instead of mild steel to oreventcorroston. Lowerunit cost,for exampleusinga single-piece componentinsteadof one that needsto be assembledfrom severalDarts.to make it faster to oroduce. Make lifeeasierfor user,for exampledesigning a simplercontrolpanelthat'squickerand easier to use,or maintenance-free componentssuch as bearingsthat don't need lubricatingregularly. Examplesof other pointsthat couldbe added: make productsfunction more effectively,make them safer,makethem last longer,makethem more robust (stronger).
b Items2 and 7
so
66
su€ g ested answers I A hammer-action drill wouldnot be suitable for reinforcedconcrete,as there's no way it coulddrill throughthe steel reinforcingbars. Also, the diameterof the holeswouldbe too greatto drill usingan ordinarydrill bit. This is definitelynot a feasiblesolution. 2 This couldbe a feasiblesolution.However, dependingon the designof the ends of the beams, it might be difficultto get accessto the holes after the beams were fitted. lt'll be quite a painstakingjob, as the beamsmight coverthe holes,makingit impossibleto get cementinto them. 5 This isn'treallyfeasible,as the positionsof the ho|esmightbe in unsuitáb|epositions on the beams,for example very close to the edgesof plates.This wouldnot be acceptable in termsof structuralstrength.Also, drilling holesthroughsteel beamson site would
102
4
be very painstakingand time consuming comparedwith pre-drilling them during manufacturing. This shouldbe feasiblefrom a structural pointof view,but it'llcost an arm and a leg due to the needfor additionalsteelcolumns. For that reason,it is not a feasiblesolution.
Answerkey
4
No. The existingdesign has provedto be effective.The companydoesn't havethe resourcesto make fundamentalchangesto the productionprocess. Once The softwarehas been a maior weaknessof the existingmodel. - it needsto be simplerto use Significantly
d 2 3 4 5 6
inventagain improvethe details improveoverall t h i n ka g a i n stay (thesame)
e 2 3 4 5 6 7
groundup room;improvement Achillesheel back;drawingboard quantumleap scratch
2 3
f b4
g 1 J
4 5 6
13a The first mechanicalmousewas improvedby refiningits shape:by addingan additional buttonand a wheelto the top and by revamping the wheelmechanismunderthe mouse.The mechanismwas redesignedto use a ball instead of wheels,althougha wheelmechanismwas still used insidethe mouse;as the ball rolled, it causedthe wheelsto turn. For the optical mouse,the designerscompletelyrethoughtthe undersideof the mouse.lnsteadof usinga ball, they used optical sensors.They also redesigned the connectionbetweenthe mouse and the computer,makingit wirelessinsteadof havinga wire.For the touchpad,the designerswentback to the drawingboard and inventeda new system usin€ a sensitivesurface.
I
d6
e2:7
f3
Unit 7
1 Workingwith machinesthat havecuttingwheels and blades;work at a high levelwherethere'sa risk of falling;work in excavationsand tunnels wherethereis a risk of collapseor dangerous gases;lifting heavyobjectswith cranes where there is a risk of fallingobjects;processesthat use high-pressurevesselsand hoses/pipeswhere there is a risk of explosion;workingwith highvoltageelectricalcircuitswherethereis a risk processesthat use flammable of electrocution; liquidsand gaseswherethereis a risk of fire or exolosion. 2a Suggested answers I hazardoussubstances: dangerousmaterials, for example acid, asbestos;PPE: protective clothingand accessories, for example protectivegloves,safetyglasses 2 harmful;dangerousto health,for example chemicalsthat causeskin rashes;fumes: vapour or smoke,for examplefrom liquidchemicalsthat evaporateat room temperature; asohyxiationhazards: danger of suffocation,for example due to concentrations of carbondioxide/ lack of oxygen 3 fire/exolosionhazards:substancesthat could burn or explodeif exposedto nakedflames or sparks,for examplepetroleumproducts, gas,alcoho butane/propane 4 guards;protectiveshieldsarounddangerous machineparts,for examplethe guardsover the tops of circularsaw blades 5 guardrails:railsat waistlevelto prevent peoplefrom falling,for examplealongthe edges of high-levelwalkwaysand platforms; emersencyexits: doors to allow rapid escape/ evacuation,for example fire exits 6 electricalinstallations: situationsinvolving contactwith exoosed electricalconductors suchas electricalmaintenance or work operationsc|oseto hi€ h -voIta€ e cabIes 7 noisehazards:loud noisethat can damage hearing,for exampleloud machines b
c5
This is the oroduct'sAchillesheel. There'sno pointreinventing the wheel. We started from the ground up with this new design. The newdesignis a quantumleap. I thinkthere'sroomfor improvement.
b7
cl
d3
c 2e 7h
5b 8c
4C
5f
6a
d ear protection,gloves,eye protection,mask
e
sug€ e sted answers 1 This is a confinedspace.You need to test the air using a CO2 detector. You needto 2 This is a corrosivesubstance. wearglovesand eye protection,and a mask for orotectionfrom the fumes. 3 This makessDarksand is a noisehazard.You need to wear eye protection,ear protection and gloves. You needto wear 4 This is a harmfulsubstance. gloves,and if there'sa risk of splashing,eye orotection. 3a Suggested answers of the dangers I An analysis/prediction involvedin a workingoperation 2 A safeworkingprocedure/method work,whichincludes 3 Some maintenance welding,is goingto be carriedout in the bottomsof some largegrainsilos(silo = storage tank for solid substances/ powders) 4 Cettinginsidethe silos 5 See audioscript7.2 on page9l b I 2
c I
Risk of someonefalling;risk of gas bottles fallingon someone COr; fumesfrom metal;dust (explosion hazard) Access hazards:externa|stáircaseand internal ladder for safe accessfor workers, lowerbottlesinto silo witha rooe and make sure no workersare underneathin silo. Confined space hazards:use a CO, detector, use an air extractor. An air extractorcouldblowdust into the air and makethe problemworse.
4 One of the main dangers is from petrol fumes insidethe tank,as there'sa risk of explosion due to sparksand flames.The workerswill have to be carefulthat there's no oetrol inside the tank.The petrolwill haveto be drainedand the insidewill needto be washedout withwaterand detergent.The openingcan then be flame-cut throughthe steelwall of the tank usingan oxyacetylenetorch.PPE requiredfor this job is eye protection(a weldingmask),gloves and heavy overallsto protectthe worker from molten metal. Alternatively, the cuttingcan be donewith an To be safe,the workerusingthe angle-grinder. grinderwill needto weareye protection,ear protection,gloves and overalls.When welding the new pipe,the welderwill needto weareye protection(a weldingmask),glovesand overalls. lf arc weldingis usedand thereare other people workingnearbyor passingby,screensshould be placed around the welder to protectother peoples'eyes from flashes.When shot-blasting, the main dangersare to the eyes,and from noise and dust.Screensshouldbe placedaroundthe area and workers should wear eye protection, ear protection,dust masks,glovesand overalls. Before painting,it's importantto read the safety documentationprovidedwith the paint, as PPE may be required- for example,gloves, eye protectionand possibly masks to protect workersfrom hazardousfumes.During all the operations,if any work is carriedout morethan
should two metresabovethe ground,scaffolding be orovidedwith handrails.as thereis a risk of falling(workersshouldnot standon ladderswhile working).Also, all workersshouldwear hardhats. 5a and highI Maintenancework on low-voltage voltageelectricalequipment 2 Changingfaultyor worn-outelectricalparts, suchas motors;repairinglooseconnectsor damagedwires b Suggested answers I A placewherea seriousdangeris present 2 A writtenform givingpermissionto work in a restrictedarea 5 The personresponsiblefor electricalsafety for the wholeplant,and the only person authorisedto issueoermitsto work 4 The procedureof havinga singlekey to ensuringonly one personhas switchboards, accessto switchgearat any giventime c I at all times shouldanvone 2 Underno circumstances 3 everysingletime just 4 a single 5 it'svital d I 2
more more
3 4
less more
e 2
to test the circuitis lt's crucial/essential/vital isolated. 3 The alarm shouldbe reseteverysingletime you start the system. to check that the 4 lt's crucial/essential/vital cableis not damagecl. that you shouldonly 5 lt's crucial/essential/vital materialsin this zone. storenon-flammable shouldanyoneenter 6 Underno circumstances the restrictedareawithoutoermission. 7 Before pressurisingthe system,every single connectionmust be tight. 6c Suggested answers I lt's essentialthat the crewobtaininformation on weatherconditions.lt's crucialthat pilots are highlytrainedand experienced.lt's vital that a tensionreleasemechanismis in place. shouldooeratives 2 Under no circumstances work on the linewithoutwearinghot suits and eye protection.lt's vitalthat the creware highlytrained. 5 The cablesand platformmust be checked everysingletime theyare used.lt's vitalthat helicoptersare usedand these twin-engine mustbe maintainedto the higheststandard at all times.
Í
Beforestartingwork, it's vital to isolate the Then,circuitsshould circuitat the switchboard. be systematicallytested to be I 00o/osure that there'sno current.Duringwork,it's essential to tightenconnectionsfully.And it's crucialto ensurethat no insulationis damaged.Tofinish, all the wiresshouldbe checked- underno shouldtherebe any loosewires. circumstances tested. Thenthe circuitshouldbe systematically 7d I Collisionswiththe lineare a hazard,so it's essentialto havedetailedweather information, especiallywinddirectionand soeed.lt's essentialthat the cable has a tension releasesystemin case of snagging.
The engineerswear hot suitsthat channel the electricityand havea fireproofliningto protectagainstheat. 3 on|y twin-en€ i nehelicoptersare used and theyare fullymaintainedto aviation regulations.
2
8 Regulationsare laws;they are compulsory.For example,if companiesbreach(break)safety regulations, they can be fined (givenfinancial penalties)and, in seriouscases,managerswho are responsiblefor breachesof regulationscan be € i ven prisonsentences.Standards,such as qualityand designstandards,are sometimes for examplethe designand compulsory, manufactureof motorcyclehelmetsor car tyres. Sometimes,however,theyare optional,for exampleISO qualityassurance. 9a Suggested answers - no smoking,the provlsion Risk of fire/explosion equipmentand training.Dangerof of fire-fighting peoplefallingfrom tall structuresand Intowater - handrailsrequiredto giveedge protectionand life.iackets needto be wornin certainsituations. Risk of skin irritationsfrom petroleumproducts - glovesand overallsrequired.Risk of air crashes as helicoptersland and take off from platforms - specialtrainingrequiredfor pilotsand special precautionsneededfor safe operation of helidecks. b I 2 3 c
Specificsafety regulations Compulsorypersonalprotectiveequipment; prohibitedactivities,suchas smoking That the obligationsare legal requirements 6 7 8
legislation contravene complywith
5
compursory prohibited requirements stipulated
d 2 3 4 5 6 7
permitted complywith stipulated contravene requirements; obligations legislation; compursory
3
10a 5 2 stipulated 3 compulsory 6 4 legislation 7
b I
2 3 4
t2 I
2
complywith requirements obligations
to give the ground crew access to all parts of the helicopter to avoidrisk of collisionsduringtakeoff/ landing to avoidrisk of collisionsduringtakeoff/ landing to tie down parked helicopters Safetywarnings,operatingprecautionsfor machinesand maintenanceinstructionson machines Effectivenotices and instructionsare as shortas possible,use clearlanguage,and emphasiseimportantpoints,for example dangers.
13a Coulddo both Coulddamagethe machine c Could injureworkers o Coulddamagethe machine e Coulddo both h
Answerkey
103
b I 2
danger important
14a I Becauseit containselectricaleouiDmentand couldcauseelectrocution 2 A carbondioxideextinguisher; carbon dioxidegas does not conductelectricity 3 Theyare for liftingthe machine. 4 The machinecouldbe damagedby the lifting force,and if liftedfrom anchorpointsthat are not secure,couldobviouslybe droppedfrom a heightas a result. 5 Becauseit coulddescend,and injurethe personcleaningthe machine 6 Theremay be sharp metaloff-cutsbelowthe bladewhichcouldcut the personcleaning the machine.S/heneedsto wear sloves. b I 2 5
sp: active (Youshould do it) wr: passive (lt should be done) sp: contractions(shouldn't,it's) Wr:Wordpairs Writtenin Íu||(shouldnot, it is) lf (sp): intheeventof (wr);because(sp)= os (wr);so (sp) : therefore(wr);can/could [sp) = moU [wr]
15a Suggested answers Objects should not be placed in front of the air inlet. The inlet grille should be kept free from obstructions. and should be cleoned regularlg. ln the event of damage to the inlet grille, the blower must be stopped immediatelA. Serious harm mag be caused bA foreign bodies enteringthe duct, os the unit contoinsprecisionengineeredparts revolvingat speed, and is therefore highlA susceptible to damoge. Before starting the blower, it is important to ensure that the externol vents at the end of the air-intake duct ore open. When opening the vents, the adjusting handle should be fullg extended. When closing the vents, the handle should be turned and allowed to return under the force of the spring. The handle should not be pushed, as this mag strain the spring mechanism, and therefore result in damage.
I
Unit 8
7 An automatedsystemcan function autonomously, withouthumancontrol.A manual systemrequireshumancontrol.A Building ManagementSystemis a centralisedcomputer systemthat monitorsand controlsa Wideran€ e of functionsin a largebuilding,suchas the lights, heating,air-conditioning, smokedetectors,fire alarms,liftsand securitysystems. 2a I lt's a very green/environmentally orientated company. 2 Energysavingwill be an important consideration in the design. 3 Sensorsthat detectthe presenceof people 4 He wantsto presenttwo differentdesign optionsto the client.He describesoptionone as a building with maximum automation. b 1,/ c 2 3
2,/
reading regulate
3x 4 5
4,/ detect;pick up set off; trigger
d 2 3 4
Answerkey
5 6 7
detects;triggers set off regulate
e Suggested answers '| Presencedetectorsoick uo movementand can activatelightswitches. 2 Smokedetectorssensesmokeand trigger fire alarms. 3 Thermostatscan regulateroomtemperature by controllingelectricconvectorheaters. 4 Pressureplatescan detectthe weightof a personand set off intruderalarms. 3a I That the greenattitudeis sharedby all the staff,so they would take care to switchoff lightsetc.and so there is no needto control everythingautomatically 2 lnsteadof automatingeverything, they would haveold-fashioned manualcontrols. 5 The advantageof operatingthe lights,etc. manuallyis that there'sno needto supplyall the automatedcontrolswith electricity. The moneysavedby not havingto buy all the hi-techgadgetscouldbe spenton planting trees,for example. 4 Suggested answers A thermostatmeasuresand controlsthe watertemoeraturein a boiler.and thereis also sometimesa pressuresensorfor safety. A thermostatmeasuresand controlsroom temperaturein a heatingsystem.A refrigerator also has a thermostatto monitorand control the temperatureand a lightthat is activated by the door opening.Washingmachineshave thermostatsto controlthe temperatureof the waterinsidethe machine.The time of the wash cycleis also controlled.The actionof the drum is linkedto a safetydevicethat preventsthe door f r o mb e i n go p e n e dW h i | teh e d r u mi s s p i n n i n € ' 5a 1e b I 2 3 4 5
2b
3a
4d
5c
pressuremeasurement, for example monitoringthe pressureof air insidea comoressedair hose for example temperaturemeasurement, measuringthe temperatureof waterin a boiler flow for examplemonitoringthe amountof f u e lf l o w i n ga l o n ga f u e lp i p ei n a n e n g i n e levelmeasurement, for examplemonitoring the levelof fuel in a fueltanf. processrecorders,for examplemonitoring the rejected(broken)itemsin a production process
6a a A blockagein a pipe causinga build-upof Dressure b A safetyvalveand a warningsystem triggeredby a pressuredifferential c A systemfor monitoringgas consumption d Cumulativeconsumption. the rate of consumptionat differentpointsin time,and the frequencyof peaksin consumption e A timescale f An exothermicreaction g The temperatureof gas at the input point, and at the outoutooint h The optimuminputtemperaturefor the gas b 2C tf
104
control senses reading
3a 8j
4t 9b
5c l0 e
6d
c 3 4 5 o
consumption 7 cumulative 8 rate 9 timescale l0 cycle
frequency input output optimum
7a Suggested answers We needa meter/sensor to measure:the rate of flowof waterat the inputpoint;the water temperatureat the inputpoint;the rate of flow of gas at the inputpoint;the temperatureof the gas burner;the watertemperatureinside the vessel;the levelof waterinsidethe vessel; the steampressureinsidethe vessel;the steam temperatureinsidethe vessel;the steam temperatureat the outputpoint;the steam pressureat the outputpoint;and rate of flowof steamat the outputpoint. b Suggested answers The cumulativeconsumptionof waterand gas; the cumulativeoutputof steam;the peak rates of consumptionfor waterand gas;peak steam output;the frequencyof gas use / firingof the burner;the differential betweenwaterinput temperatureand watertemperatureinsldethe vessel;the differential betweensteampressure insidethe vesseland in the outputpipe;the differential betweensteamtemperatureinslde the vesseland in the outputpipe. 8a See audioscript8.5 on page92 b 1 2 3 4 5
temperature lightlevels day of the week mealtimes commercialbreakson TV
c I 2 3 4 5 6
increase increases; decreases rise rises falls rise;fall
d I 2 3
e z É I Í
Becausemaximumcapacityis equivalent to peakdemand,thereis significantspare capacityduringoff-peakperiods. Beingable to generatepowerduringoff-peak periodsand storeit for peak periods Becauseelectricalchargeis extremely difficultto storein largeamounts. 3d 8e
4a
5b
6h
Í
Suggested answer Thereis a band of fluctuationbetween approximately 2,700 and 5,000 Megawatts. Peakdemandoccurseachday at about 8.00 pm, whenthere is a very brief blip.The graph showsa trougheach night,whendemandfalls significantly. At the weekend,the rangeof fluctuationis smallerthan it is duringthe week. Fluctuations in demandare continual- thereare no oointswheredemandremainsat the same , levelcontinuously for a long periodof time. 9a 2 peakdemand 5 continual 4 bllps
5 6
fluctuations range
b I
Operating on a start-run-stop-wait basis Momentaryblips in demand Frequencyof the AC (alternatingcurrent) supply A slightdrop in frequencyindicatesthat power stations are working at full capacity. Start-upof appliancesis delayedslightlyby holdingthe applianceon standby
3
10a I Demandfor electricityfluctuates, and powerstationsneedto be able to copewith peak demand(at the top of the rangeof fluctuation). The problemis that the peak only lastsfor a very briefperiodeachday, meaningthat powerstationshavea lot of generatingcapacitywhich,mostof the time, is not used.Therefore, electriccompaniestry to smoothdemand- usingsparecapacity duringdemandtroughs[atnight)to storeup energy,whichis then usedthe nextday when demandpeaks. 11a I A seniormanager 2 A reviewof the company'sorganisation and facilities 3 Optimisingefticiency / the use of engineers' skills b I c
2b
3a
c
'|
2 3 d 2 3 5 6
A: 50o/o B: 50o/o A:7Oo/o B:3Oo/o A: l0o/o B: 90o/o off the top of my head pretty much nownere near roughly / somewhere in the region of roughly / somewhere in the region of
12a IT 2T 3 F - they print very few copies
b I 5
4 5 c 3 4 c
6 7 I
roughly wellover a good the vast maiority next to nothing Pretty much Nowherenear Roughly/ somewherein the regionof Well over Next to nothing Rough|y/ somewherein the regionoÍ the vast majority
3
sized prototypes.The main disadvantage is that their behaviourduringtestscannot perfectlysimulatethat of a fulFsize prototype. The mainadvantageof this approachis that testsare totallyrealistic.The main disadvantageis that full-scaleprototypescan be expensiveto build and test.
2a Computational Fluid Dynamics(CFD)is computer softwareusedto assistin aerodynamicdesign.lt modelsthe flowof air oversurfaces,suchas car bodyworkor the fuselageand wingsof aircraft. Virtualtestingwith CFD softwareis typically done in the earlystagesof the designprocess. Wnd tunnelsequippedwith rollingroadsallow reduced-scale modelsof vehiclesor full-size vehiclesto be tested.Air is blownthroughthe tunnel by powerfulfans to create airflowsof differentvelocitieswhichsimulatethe vehicle travellingat differentspeeds.The airflowover the surfacesof the vehicleis highlightedwith streamsof smoke,so that it can be analysed. A ro||in€ road is effective|y a conveyorbe|t whichmovesbeneaththe stationaryvehicle at the samespeedas the airflow,makingthe wheelsturn.This allowsengineersto analyse the effectsof the spinningwheelson the airflow. Fieldtestingrefersto testingin real conditions. For aerodynamic testingof a vehicle,this might involvedrivingthe vehicleat differentspeedson a circuitor runway. b I 2 3 4 5 c 2 3
Usinga scalemodelor a full-sizemock-up To simulatethe turbulencecausedby wheels whenthey'respinning Whetheror not the wheelsare mostly enclosedby the bodywork Theyare not a hundredpercentreliable;the data needsto be validatedby full-scaletests in real conditions. Changeableweathermakesit difficultto do back-to-backtesting
5
mocK-up validate acid test;tried-and-tested; trial run back-to-back testing;in the field
d b c d e f g h
tried-and-tested in the field virtual the acid test back-to-back testing validate trial run
e 2e
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4d
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loc
First,testingof the parachutecouldbe done usinga weiehtto simulatethe massof the Unit 9 container. The Wei€ h t shou|dbe so|idand 1 unbreakable, for examplea blockof steel,to Suggested answers allow severalparachutesystemsto be tested I Usingsoftwareto simulatereal-lifesituations. back-to-back withoutdestroyingthe container The mainadvantageof this techniqueis that eachtime.For tests,the weightand parachute testing is often faster and easier to undertake could be dropped from a raised platform comparedwith real-lifetesting.Variables attachedto a crane.Initially, the aim of these testswill be to developa parachutesystemthat can also be changedeasily.The main disadvantage will slowthe container'sfall as muchas oossible is the lowerdegreeof realism. 2 Testingsmallmodelsofdesigns.The main to minimisethe verticallandingspeed.Once advantageof this approachis that models the parachutesystemhas beendeveloped,and quicker are the verticallandingspeedhas beendetermined, and cheaperto build thanfull-
I
testscan then be carriedout on the container and deformablestructureby simulatingthis knownlandingspeed.Initiallytherewill be no needto use the parachute.as the containercan be allowedto freefallfrom the crane - the droD heightbeingset so that the verticallanding speedis the same as that reachedwith a parachute.lnitially,reduced-scale, for example half-size, mock-upscouldbe tested.Thenfullscaletestscan be carriedout. The container designcan then be testedwiththe parachute by droppingit from the crane.This will help to simulatethe effectsof the wind blowingthe parachuteand container,thus generatinga horizontal[aswell as vertical)landingspeed. Finally,for the acid test, real lifetrial runs can be carriedout usin€ an aircraftto Va|idatethe tests. 4a Suggested answers I Humanitarianaid, for examplefood and medicine,and militaryequipmentare often airdropped,as theyfrequentlyneedto be deliveredto remotelocationswith limited transportlinks. 2 The main advantageis that planesdo not need to land and take off again to drop off cargo,savingtime and fuel.The main disadvantageis the difficultyof protecting cargo from impact damage. b I
decrease- As long as the containerremains in the air, its airspeed(itsspeedrelativeto the movingair in the atmosphere)will keep decreasinguntilit has an airspeedof zero - until it is travellingat the same speedand in the same directionas the wind.Therefore, if there is a certainamountof wind,the containerwill havea degreeof groundspeed (horizontal speedrelativeto the ground),as it moveswith the wind.lf the aircraftis flying into the wind (inthe oppositedirectionto the Wind)Whenit drops the contáiner,and if the containerremainsin the air long enough,the containerwill slowdown until it momentarily has a groundspeedof zero. However,if it remainsin the air beyondthis point,its groundspeedwill then beginto increase againin the oppositedirectionto the aircraft, as it is blownbackwardsby the wind. 2 higher- The container'sverticalspeedwill keepincreasinguntil,if it remainsin the air long enough, it reachesterminalvelocit| - the pointat whichaerodynamic drag [air resistance)preventsit from travellingany faster. 3 and 4 This will dependon the shapeof the containerand the distributionof weight w i t h i ni t . c They agree on the first two points (horizontal speeddecreasesand verticalspeed increases). Theydisagreeon the last two points(which impactis worse,and whatwill happenon the groundwitha very low-altitude drop). 5a I theoretically 4 2 assuming 5 3 surely
presumably arguably
b I Presumably 4 2 Assuming 5 3 Theoretically
Arguably Surely
Answerkey
105
c Agree: Sure;Absolutely;True;Of course Other phrases;I totally/completelyagree Disagree:I'm not so sure ...;I'm not convinced; Not necessarily Other phrases:I'mnot sure I agree;I disagree; I totallydisagree d Suggested answers I An aircraftsgroundspeedis its speedrelative to the ground. lts airspeed is the speed it passesthroughthe air. Becauseof the wind, the air is usuallymoving.Therefore,if an aircraftis flyinginto the wind,its airspeed will be higherthan its groundspeed.lf it has the wind behindit, its airsoeedwill be lower than its groundspeed. 2 Zero 3 The aircraftwould need to fly into the wind,and the wind soeedwouldneedto be very high,higherthan the minimumspeed requiredfor the aircraftto fly. 4 lt shouldfly into the wind so that the wind helpsthe containerto slowdown. 5 Providedthe aircraftflies into the wind, higherwind speedwill resultin the container havinga lowergroundspeedon landing. However,above a certain wind speed,the containerwill reachzero groundspeed, then start to travel in the opposite direction. Beyondthis point,evenhigherwind speeds will resultin a highergroundspeedin the oppositedirection. 6b Suggested answers I The containercould be flat with a low centre of gravityso that it s|idesalon€ the ground, or perhapssphericalwith a deformable protectivestructurewhich allows it to roll alongthe ground. 2 The containercouldbe tall,for examplea cylinder shape,with a deformableprotective structureat its base to absorb the vertical impact. 7a Expectationsare what you predict,for example how you think a vehicleprototypewill behave whenit's testedin a wind tunnel.Resultsare what actuallyhappens,for examplehowthe prototypeactuallybehavesin the wind tunnel, based on the completedtest. b Trialand error meanstesting ideas to see what happens.The expressionimpliesthat the testing process is not very scientific,and is simply based on guesswork. Unfamiliar territorUmeans an unknownsubiect, an area wheresomeonelacksexoerience. On o steep learning curve means learning rapid|y,oftenas a resu|tof bein€ put in an unfamiliarsituationwithoutthe necessarv knowledgeor experience. c See audioscript9.3 on pages93 and 94 8a I Half full. 2 The openingin the bottlewas just slightly bigger than the fitting at the end of the pump, so there was quite a good seal. 3 Ouite powerful,more powerfulthan expected 4 The bottletumbledover in the air - it wouldn'tfly straight.
106
I
Answer key
b I
3
thoughUpredicted didn't expect/predict it was muchbetterthan we had hooed
9a See audioscript9.4 on page94 b Theyput a plasticbeaker,withwaterinsideit, onto the top of the bottle which made it frontheavvand increasedits inertia.
c I
accordingto plan
2 a treat
10b Seeaudioscript 9.5on page94 C 3
practrce more tess
5 6
inadequate practical
72 Suggested answeE I Possible causes:the tyre is inadequately inflatedor punctured Possible effects:the tyre could blow out (explode)/ the tyre will wear rapidly / become damaged. 2 Possiblecauses:a surgein the powersupply, too muchpowerbeingdemanded,a short circuit Possibleeffect:a circuitbreakerbeing triggered,overheatingand damage to conductorsand components 3 Posslblecause:thereis inadequatepaint cover to protectthe hull Possible effect:the hull will degrade rapidly / couldfail 13a A mistakewith a chickengun has madeclever, technicalpeoplelook like fools.
b I
3
To fire dead chickensin order to test aircraft enginesand windshleldsfor their resistance to bird strikes Becauseit was a high-speed trainand bird strlkeswerea potentialdanger The chickenbrokethroughboth the windshieldand the backof the driver's comoartment.
c They used a frozenchicken. d 2 3 4 5 6 e .| 2 3
becauseof; due to; owingto result of becauseof caused consequently becauseof / due to / owin€ to caused;consequently becauseof / due to / owingto: resultedin; consequently
14a See audioscript9.6 on page 94
I
Unit 10
1a Suggested answers I Theyuse the kineticenergy,movementof the wind, to generateelectricity. 2 Advantage:They use a renewable,nonpollutingenergysourcethat is readily available. Disadvantages:The wind is not constant,so wind turbinescannotfunctionall the time. Theyalso havea maiorvisualimpactdue to their height and size,and are relativelynoisy. 3 Locationsexposedto the wind,such as high ground,flat areas and coastal areas b Suggested answers The bladesturn due to the air flowgenerated by the wind.To function,they needto have a speciallydesignedaerodynamicprofile. They must also be stiff,to avoid flexing and consequently hittingthe tower,and relatively lightto allowthemto turn easily. The tower must be rigid, to resist the bending force generatedby the pressureof the wind. lt must also have a relativelynarrowprofile,to minimisethe aerodynamiceffectit has on the blades.Whena bladeis in the low position, alignedwith the tower,the pressureof the wind on the blade is reduced,reducingeffectiveness, and causingtorsionin the turbinedue to pressureon the higherand lower differential blades. The turbinegenerateselectricityfrom the action of spinning.To functioneffectively,it needs to minimisefriction.lt mustalso resistthe severe weatherwhichis commonin the areaswhere windturbinesare located. 2a I 2 3 4 5 6
b
lb 6d c 2 4 5
The tower Corrosiondue to the presenceof saltwater Steel and reinforcedconcrete Because in reinforced-concrete coastal defences,the steel reinforcementis often exposed,due to erosion,and rustsas a result Thatjust becausean installationrequires regularmaintenance, that doesn'tnecessarily meanit's unreliable A comoarisonof the differencebetweenthe constructioncost of a reinforcedconcrete tower and the cost of repaintinga steel tower over the period of a concretetower'slifespan 2e
3c
inappropriate6 inconsistent 7 uneconomical8 ineffective 9
4a
5f
inefficient unreliable insufficient unsuitable
d See audioscript10.I on page 94
3a 2 3 4
suitable 5 effective 6 inconsistent 7
inefficient insufficienUinadequate unreliable
I
b Suggested answers l Wind turbinesare extreme|yeíficient. They use a free, renewablesource of energy. They'realso extremelyreliable,requiringvery little maintenance. Clearly,wind turbinesneedwindto functioneffectively but wind conditionsare inconsistent. For this reason,a windturbine is a supplementary sourceof energy.lt will still be necessaryto havea permanentsupply of electricity.However,in suitable locations, wind turbines can work effectivelyfor a significantpercentageof time. The most suitablesitesare exposed locations.Sites located on the toos of hills. on the windwardslopesof hills,near the coast,or on flat,open land are the most suitable. To work effectively,wind turbines should be located awayfrom featuresthat can obstructthe wind,suchas buildingsor trees. Obstructionscan have a negativeeffectif they are locatedin frontof the turbine,and also if theyare relativelyclosebehindit.
than out-of-townairoorts. Planes also tend to be delayed more often than trains, due to air traftic congestionat airports. Large aircraftcannot take off and land immediatelyafterone anotherdue to the need for separationdistancesfor safety, and to allowair turbulencetime to clearalong the runwayafter each takeoffand landing.Also, checkingin for flightstakeslongerthan boarding trains. For these reasons,overalliourney times on high-speed trainscan be as shortas, or shorter than those on olanes over distancesof 500 kmto I,500 km. b I 2 3 c I 2 3
efficlencyand Speed,convenience, environmental-friendliness To find the best way of transportingpeople That high-speed electrictrainsare the most efficientsolution criterion factor variable
4b 10.2on page94 Seeaudioscript
6a Most TCVSreach 300 km/h.Newer models run at 320 km/hon certaintracks.Most trainsare approximately200 metreslong.
c Shedoesn'tmentioncentrifugal force.
b See audioscriptlO.3 on page94
d
c I
3 4 5 6
bénding torsion/torque expansion pressure tension
7 I 9 l0
e 2 3 4 5 6 7 I
oressure bending compression: tension shear friction torsion (torque) expansion;contraction
shear friction contraction centrifugalforce
f Suggested answers When thereis no wind,the columnsand legs are all sub.iectedto compression.The legs are also subjectedto bendingforces.The beam is subjectedto a vertical bendingforce.The insulatorsare in tension.The foundationsare in comoression.There are also shear forces betweenthe legs and the foundations. Whenthe wind is blowingfrom directionl, the beam is subjectedto a horizontalbendingforce from the wind. Both columnsare also subiected to bending.Legs I and 2 are in tensionas a resultof the wind.Legs3 and 4 are in compressron. When the wind is blowingfrom direction2, both columnsand legs are subjectedto bending by the wind.Legs 1 and 3 and columnI are primarilyin tensionas a resultof the wind.Legs 2 and 4, and column2 are in compression. 5a Suggested answers Planes travel much faster than high-speedtrains. The fastest high-speedtrains can travel at just over 300 km/h.Commercialaircraftflying at an altitude of around 30,000 feet can travel with a groundspeedof around 800 km/h.Therefore, on board trips are typically faster on planes. However,rail networksgenerallylink city centres, which are often more convenientdestinations
2 3 4 d 2 3 4 5 e 3 4
f 2 3 4 5
caoable able withstand subjectedto
6 7 8
unable incapable exceeded
9a Key information and questions The supersonicrocket sled ride for tourists is to be locatedthe Australian desert. lt is to carry a pilot and two passengers.lt must avoid extremes of C force under accelerationand deceleration (max2 G). Max track length l6 km. ls it feasible to havejust l0 km of track? ls that enough safety margin? ls the sled to have steel skids or wheels?Propulsionwill be by rocketor jet engine (bein€ |ookedinto by someonee|se).Braking system- not a water brake,as there is too much C force;possibly a friction system (againstrails), an aerodynamicsystem(flapsor parachutes), reverseenginethrustsystemor a combination of these.
lt was modifiedto a certain extent but, with a few exceptions,was essentiallyan ordinary TCV 100 metres To makeit slightlymoreaerodynamic To reducethe speedof revolution, to limit frictionand centrifugalforce - 50o/o - 15o/o + lgoh + 680/o certain 5 significantly 6 slightlymore 7
marginally substantially considerable
Í
su€ g ested answers I The supplyvoltagein the catenarycableshad to be increasedby a considerableamount. 2 To limitoscillation, the tensionof the catenarycables was substantiallyincreased. 3 The camber of the track was increased marginallyon somecurves. 4 The previousrecord was beaten by a huge margin. 5 In perfectconditions,the TCV could probably havegone slightlyfaster. 8a See audioscript10.4on page95 c 1 1 . 0 r5 23 320 4 1.2 546 e 2 3 4 5 5
cope with;withstand exceed:suroass intendedfor able to; capableof incapableof; unableto
Answer key
to7
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