Technology with Promise: A short tribute to the OxyCal

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The OxyCal: Malawi iteration

After spending time building the OxyCal prototype at Rice and then field testing it here in Malawi, I have become increasingly impressed with the group of freshmen who built this device.

They were able to speak to Joseph (a PAM technician at Queens) in the beginning stages of their project, and I can tell that this end-user input has been a key influence in the design process. I met with Joseph when I brought the device to Queens for field testing and it was really powerful for him to be able to hold a prototype that had only been an idea less than a year ago.  The device measures the oxygen concentration being outputted by an oxygen concentrator for a tenth of the price of the standard oxygen analyzer used here, the Handi+ ($20 vs $200).   The need for the device is so obvious, too.  PAM only has two working Handi+ analyzers in the entire country of Malawi, one at Queens and one in Lilongwe, but being able to measure the concentration is essential to oxygen concentrator maintenance and repair.  The team has received a grant and their device definitely has a lot of potential.

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Joseph and I using the OxyCal to test a concentrator in the PAM workshop

I really  appreciate the opportunity that professors Saterbak and Wettergreen  provided these and so many other students in their first year (including myself) through their freshman design class ENGI 120. It’s a completely hands-on way to learn the design process by being able to design something for a real customer.  Basically, Rice University is a wonderful place full of wonderful people. 🙂

Progress

After travelling to several small hardware and household supply stores in Limbe, we selected eight locally available filter materials: thin foam, cloth, wire mesh, a green scrubbing sponge, thick foam, a standard yellow sponge, steel wool, and a sponge covered in cloth.

IMG_2080The eight filter materials cut for testing in addition to a NewLife Intensity filter

Though we struggled to create accurate testing set-ups using available resources for  a while, we came up with a simple ping pong ball airflow test and a dirt retention test using weight measurements before and after a set amount of dirt was sucked through the filters with a vacuum. Our goal was to compare the performance of each material to the performance of the NewLife Intensity (an oxygen concentrator model) filter.  We used our results as well as a wash test, drying time, cost, availability, and ease of use to select the winning filters: the yellow and green sponges.

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Our airflow test set-up (the filter is inside of the black adapter)

As far as sieve bed regeneration goes, we bought a clamp that makes opening the sieve beds much easier and therefore much more feasible.

IMG_2171Vincent opening a sieve bed with the clamp

By contaminating sieve material with water and measuring it’s performance in a concentrator before and after regeneration we were able to prove that our oven method can bring the output oxygen concentration from 39% back up to 80%.  Unfortunately, this is still considered below optimal output.   We think that this could be due to several factors.  First of all, we are testing on a concentrator that had been broken for years already, so we think there may be some other points of failure contributing to the low output.  Also, we noticed some fine dust in the sieve material that should be removed for optimal performance.

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Dust among the spherical zeolite

We have also worked on creating an intake filter and our education project, which you will find more about in later blogs.   As the end nears, I feel like there is so much more we could do with more time.  However, our work has had much more depth than just a couple of simple projects. We are making a big effort to set up projects in such a way that they will be easily picked up again by others.  Though the biomedical engineering program at the Poly is new, the interns we’re working with are electrical and mechanical engineers who have really enjoyed all of the work we’ve done together. The relationships forged between the hospitals and the Polytechnic are key for future collaboration on projects, which I’m confident will continue to grow in frequency in the coming years.

Moving Forward

Upon return from our site visits we compiled observations, evaluated needs, and generated several project ideas.  I chose to work on the oxygen concentrator projects which include sieve beds, filters, and education with Vincent, Harvey and Christine.

Though the problem with a specific concentrator was difficult to pinpoint by the technicians at Zomba, they mentioned that contaminated sieve beds and worn compressor parts are the most common issues. They estimated that sieve beds were the issue about 50% of the time.  This is due to the aluminum silicate binding with water in the air.  We are exploring methods of zeolite regeneration, so that sieve beds could be reused instead of being replaced by the manufacturer.  So far the method of opening up the sieve bed and heating the zeolite for several hours seems promising, but we doubt the feasibility of this extensive process in a hospital or PAM workshop setting.  Heating gas and running it through the sieve bed itself would be better, so that the canister would not have to be opened.

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Fun opening sieve beds

Lack of filters was not mentioned as a common mode of failure, which may be due to the fact that it is a cause of contamination, but not the part of the concentrator that actually breaks.  Mr. Khonje did mention that the bacterial filters were black from use and should be replaced periodically, but that they do not replace them. We noticed that most of the concentrators did not have their original gross particle filters, and Mr. Khonje said that they had been lost in the ward. However, for some of the concentrators, he had improvised a new gross particle filter out of a yellow piece of foam.  Similar improvisation attempts were also observed at the other sites, so we decided to take on the project of finding the best local material for filter improvisation. We walked around Limbe for a few hours, going into all of the hardware stores and looking for materials that could be used as a filter.  We found several candidates, including different types of sponges, foam, cloth, and wire mesh.  We have developed tests to evaluate the different materials based on dirt retention, airflow restriction, drying time and durability.

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A very dirty concentrator missing both the gross particle and intake filters (are you surprised it’s broken?)

IMG_9774A gross particle filter improvised by Mr. Khonje

In order to ensure the sustainability of our filter solution, we are developing simple, pictorial instructions for basic cleaning procedures (like washing the gross particle filter).  These instructions will be laminated and fixed to the concentrators in the wards so that nurses and cleaners will be aware of the periodic maintenance which could prevent so many concentrators from failing.  We have already seen different examples of pictorial instructions around the hospitals (some are shown below), so we are hopeful that they will be effective.

 

 

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The Futility of Donation

The most powerful part of travelling to Zomba was getting a true grasp for the importance of Rice 360.  Walking into the PAM workshop, the shelves full of broken medical equipment were initially pretty overwhelming.  Fine dirt covered every concentrator, similar to the dirt on the ground outside that blows onto everything and covers my shoes when I walk.  I didn’t know how long it would take to assess all of the concentrators, open them for measurements, and close them again.  Our task was made more difficult by the variety in concentrator models.  Mr. Khonje said the hospital buys DeVilbiss 525KS concentrators, but the others were donated and commonly failed more quickly- specifically the Invacare Platinum XL, which tends to fail within a year of donation in comparison to the 5-10 years of the DeVilbiss.

IMG_9782Shelves plus Kate

           Inside the shop was an incubator that immediately caught my eye because it was the first piece of thermoregulatory equipment I had seen at Zomba.  I asked if it was broken too, to which Mr. Khonje simply responded, “No.”  Confused, I then asked why it wasn’t in use.  He said that nurses rarely use incubators at Zomba Central Hospital because they require too much concentration and monitoring (are difficult to use).  He said they don’t trust themselves because of the fear of “cooking the baby”.

IMG_9801An incubator sitting untouched in the nursery ward

          Walking to the back door of the workshop, I looked outside and saw what was essentially a junkyard full of medical equipment- large, expensive, and broken.  As I began talking to the technicians and nurses, I realized there were so many things about these contraptions that just weren’t practical in this setting.   It didn’t matter how much equipment was donated, how new it was, or how much it cost.  It is ignorant to hand what works well in one part of the world to someone else in an entirely different environment and assume it will benefit them similarly.  There is a need for personalization of equipment through root-cause analysis of specific challenges and sustainable redesign.  Rice 360 truly takes into account the needs of the end user, and I am glad to be a part of this program.

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Part of the junkyard

 

Zomba

This post is about a week late- it’s taken a while to process all of our site visit information.  Also, the Rice University provost, Dr. Richards-Kortum, Dr. Oden, Dr. Leautaud, and some medical doctors interested in the program have come to Malawi for a few days so we’ve spent some time talking to them about our projects and getting great feedback and advice.

The road to Zomba was long.  It took about an hour to get there every morning, and I often found myself drifting into sleep to the sound of BBC radio.  It was strange to hear about the Orlando shooting occurring at home through British broadcasting in a car in Malawi.  A Polytechnic lecturer named Joseph traveled with us every day and was very helpful.  The first morning he described an experience he had in Zomba a few years back when he played football (soccer) for school.  He said the Zomba team had placed a witch doctor behind their goal because they believed it would help them win, jokingly commenting that it must’ve worked because his team lost.

When we reached the hospital, we went straight to the PAM workshop where we met Mr. Khonje, a PAM technician.  At first the sheer number of broken concentrators was overwhelming, but Kate and I just began systematically taking them off shelves and going through our log for each one.  We soon discovered that we needed to reevaluate the questions we planned on asking.  While Mr. Khonje was able to give us details about a concentrator that had broken two weeks prior, the others had been broken at least six months (most about a year) before.  In the absence of newly ordered parts, the technicians had stripped several parts from the broken concentrators in the hopes of using them to repair other broken concentrators.  Without flow meters, oxygen sensors or pressure gauges to pinpoint the issue with a concentrator, the repair protocol used by PAM is to switch out parts until the concentrator operates properly.  However, proper operation can only be gauged by the absence of low output alarm lights, and the presence of flow that can be felt by hand.  For these reasons, we were unable to get details about the other concentrators from the technician, only our own measurements and observations.

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Looking at a concentrator in the PAM workshop

          We also looked at concentrators in wards and methods of thermoregulation in the nursery, labor, and KMC wards.  We were able to interview several nurses, three mothers, and a nursing student.  We noticed that the walls were covered in information including the importance of thermoregulation, ideal temperatures of babies,  ideal room temperatures, KMC tips and danger signs to look out for during KMC.  The nurses were very knowledgeable about hypothermia, most problems seemed to arise from lack of equipment like thermometers or working resuscitators which were used to heat babies.  According to a nursery ward nurse, babies weren’t wearing hats due to difficulty affording them (they cost about 1500 kwacha each).

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Typical beds in the nursery

IMG_9795Danger signs of KMC posted in the KMC ward

           Overall, it was a great learning experience to be able to assess needs based on my own observations.   I emphasized my role as an engineering student looking for project ideas, not evaluating or “grading” the nurses and other staff in any way.  This was the first time the program included site visits, and I am hopeful that our trips have helped build up the relationship between the Polytechnic (and Rice) and the hospitals we visited.

 

 

 

Preparing for Travel

Next week we will be travelling to other hospitals in pairs.  I am travelling with Kate to Zomba, where we will perform oxygen concentrator tests and observe a few wards.

This past week, we have been extensively studying the components and operation of oxygen concentrators.  We have read through user manuals, taken measurements on some broken concentrators that are in the design studio, and opened them up to analyze their parts.  In preparation for our trips, we have created a data log to record the oxygen concentrations and flows being outputted by the machines we encounter, among other measurements.  One of the four toolkits we created for each team is pictured below.

 

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Oxygen sensor, pressure gauge, flow meter, DMM, tubing, screwdrivers, etc.

While we have learned a lot about repairs, we will be working alongside the PAM (Physical Asset Management) technicians, who maintain medical devices in Malawian government hospitals, to do any repairs (not performing them ourselves).  Independently, we will be working on diagnosing the issues we find and creating a detailed database so that when we return to the Poly, we can determine common issues occurring as well as their frequency, and perhaps find some non-traditional solutions.  We want to especially focus on making them easier to repair locally, because having to order parts is not ideal in this setting.  Of course, in addition to any suggestions we make, Matthew Petney has asked us for a detailed risk assessment, as we will be proposing alternatives to standard repair methods.

Our observations in the wards are focused on the treatment of neonatal hypothermia.  Hypothermia in neonates is a known issue in low-resource settings, but lacks research and low-cost solutions.  While several devices have been designed to aid in the thermoregulation of neonates in low resource settings, not many studies exist comparing the effectiveness of each one.

Preventing hypothermia boils down to the methods of heat transfer: conduction, convection,  and radiation.  Within each of these categories lies a plethora of minute details which must be accounted for to prevent heat loss.  For example, if a newborn is placed on a scale for a few minutes after delivery while the mother is still being cared for, any contact with the cold metal of the scale will draw heat from the baby.  Any draft in the room as well as washing the baby too soon after birth facilitates heat loss through convection.  Drying and swaddling is a standard method for hypothermia prevention, but this is much less effective if the baby is swaddled in the same cloth that was used to dry (common if only one cloth is available).

We will pay close attention to every detail of the babies’ setting: proximity to open doors or windows, ambient temperature of the room, etc. Behavioral factors like temperature measurement methods are also important.  We visited the neonatal ward in Queen Elizabeth Central Hospital today, where we noticed that only one nurse was on duty in a large room full of neonates.  Most care was provided by mothers.  We spoke to a few, who said that they measured their baby’s temperatures with the backs of their hands, a common method where thermometers are not available to every mother.  We are hoping to shadow a nurse in the ward, speak to some mothers, and maybe even observe a delivery to better understand common thermoregulation practices.

Meanwhile in Malawi

My first week or so in Malawi has been incredible.  The scenery is breathtaking- full of mountains, green plants, red dirt and a sky that seems more blue than anywhere else.  In contrast to Houston, the night sky is full of stars and the weather is cool and breezy.  We have gone to the market for fresh fruit and we eat traditional Malawian food for lunch on weekdays at the Polytechnic.  Nsima (pictured below) is an exceptionally filling traditional food made from maize flour.

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     A typical lunch with beans, greens,                               and nsima

 

Our first week at the Poly, we met several professors who are all very friendly and extremely willing to help.  Our supervisor Matthew Petney, who runs the Polytechnic design kitchen and teaches design courses, has generously offered  to teach us more LabView and Arduino, among other skills.  We have also learned a lot about the culture and living in Malawi from Matthew, who has been here since last August.  [Like the Malawi Polytechnic Design Studio on Facebook! (: https://www.facebook.com/PolyDesignCenter/ ]

This week, the Malawian interns who are working with us this summer arrived.  There are now eight of us in total, and we are living together in the Polytechnic guest house.  So far has been wonderful getting to know them, and our adventures in learning to cook have brought us together as a community (Fun fact: apparently cooking times and temperatures increase at high altitudes and we are 3000ft above sea level).  They also taught us a card game similar to Uno, which was really fun.  Leah, Christine and I decided to do Insanity workout videos to improve our poor hiking abilities and Kate, one of the Poly interns, is going to join us tonight after seeing that we didn’t pass out during the first workout yesterday.

I’m looking forward to work picking up, but I’m also glad that we took the time to slow down, adjust, and absorb the environment.  It’s even better than I imagined.

Layover in London

          Most of the other interns and I left home for Malawi yesterday, and we are currently sitting in Heathrow Airport during a six hour layover.  Our next flight is eleven hours to Johannesburg, and our final flight is just two more hours to Blantyre.  It’s my first time overseas, and I have to say it’s all very surreal.  After orientations and countless conversations about Malawi, I know there are still several things that will catch me by surprise, but I am feeling very open and excited.

          The past few weeks, we have been in the OEDK assembling devices to bring to Malawi for feedback.  These include (but are not limited to) a low-cost oxygen sensor called the OxyCal, a Kangaroo Mother Care monitor, a 3D printed foot with changeable wound inserts to educate diabetic patients about wound care, a CPAP heating sleeve, a pneumatic compression device, and a mechanical breast pump.  Below are some pictures of the prototyping process:

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The specific wound insert I painted for each foot

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Learning to solder for the OxyCal prototype

         In addition to prototyping, I’ve been learning a pinch of Chichewa.  Although most people in Malawi speak English, I would love to learn as much Chichewa as possible.  So far I’ve mastered the typical greeting:

Hi – Moni

How are you?- Muli bwanji?

I’m fine, and you? – Ndili bwino, kaya inu?

I’m fine, thanks- Ndili bwino, zikomo.

Goodbye- Zikomo, ndapita

          I’m really looking forward to the next two months and I’d like express my gratitude to my sponsors, Hunter and Kerry Armistead, as well as all of the OEDK and Rice 360 staff for their help and support in making this trip possible.  It’s going to be an awesome summer!  Feel free to comment any questions you have along the way.