A.V.C COLLEGE OF ENGINEERING MANNAMPANDAL DEPARTMENT OF MECHANICAL ENGINEERING 14 th Batch

TEAM MEMBERS X.ALLAN ROY P.ARUNKUMAR R.ARUNKUMAR D.SANTHOSH Under the Guidance of External Guide Internal Guide Mr. M.Rajakumar, Mr.A.Hajamaideen.M.E., Sr. Manager, Sr. Lecturer, BHEL, Trichy. A.V.C College of Engineering, Mayiladuthurai.

FLOW OF PRESENTATION  Project title  Objective  Methodology  Diagrams  Conclusion  Future Scopes

PROJECT TITLE 3D MODELING & FINITE ELEMENT ANALYSIS OF 14” & 10” CLASS 3500 GATE VALVES. CARRIED OUT AT : BHARATH HEAVY ELECTRICALS LTD.,(BHEL) TRICHIRAPALLI

OBJECTIVE The main objective of the project is, To design the 3D modeling of 14” Class 3500 Gate Valve and 10” Class 3500 Gate Valve and analyze the internal stresses formed in the inner parts of gate valves.

In this project, the stress pattern and deformation of existing 14” class 3500 valve (Proven Design) is analyzed and the same criteria is applied to 10” class 3500 gate valve (Developed). The 14” gate valve is presently running in 55- mw captive power plant in Chhattisgarh. And also the Power Plants in other states of India like Orissa, Andhra Pradesh, Lucknow are using this 14” gate Valve in Steam pipe line of boiler. The 10” gate valve to be designed by us should be used in the place of 14” gate valve with same stress and deformation.

The developed 10” valve is also going to be used in “Krishna Patla” Power plant in Karnataka and also to the other power plants in India. Assembly models have been generated with UNIGRAPHICS 4.0 and analyzed in ANSYS The deformation and stress concentration at various zones of the proven valve should be in the allowable limit for the safe design.

Company Profile Bharat Heavy Electricals Limited (BHEL), established in 1953, is one of leading power generation equipment manufacturers in the world. BHEL has 14 manufacturing units, 13 Regional Operation Divisions and more than hundred "service-at-sites" facilities spread all over India. BHEL Tiruchirapalli has equipped all its units with sophisticated world class machinery, which form the heart of the manufacturing system.

BHEL is the first state-owned company to acquire ISO 9000 certification during 1993 for all its operations. This is being successfully maintained through surveillance and recertification audits. BHEL Trichy has been accredited to ISO Standard - signifying its clear commitment to clean and pollution free environment.

METHODOLOGY  For performing the stress analysis, solid model of the gate valve parts are modeled in the UNIGRAPHICS 4.0 software as per the given 2D diagrams.  The created 2D model is to be converted to 3D solid model by using various tools available in the UNIGRAPHICS 4.0 package for the modeling of the gate valve parts.

Main parts of the gate valves are,  Body  Bonnet  Wedge  Yoke  Stem

14” Gate Valve

Hand Wheel Stem Yoke Body Wedge Model of a 14” Gate Valve

Modeling of the components of Gate Valves Modeling of Body 14” Gate Valve10” Gate Valve

Modeling of Bonnet 14” Gate Valve10” Gate Valve

Modeling of wedge 14” Gate Valve10” Gate Valve

Modeling of Stem 14” Gate Valve 10” Gate Valve

Modeling of Yoke 14” Gate Valve 10” Gate Valve

Modeling of other parts RETAINING RINGBUSHING GLAND FLANGE WASHER SUPPORTING RING GASKET

ASSEMBLED MODEL 14” Gate Valve 10” Gate Valve

The stress analysis is to be carried out in ANSYS for the below parts Bonnet Body Wedge The model has so many curvatures and complicated profiles, then mapped meshing in ANSYS is not possible for the model. Then the only option available meshing the model in Hyper mesh software10.0.

MESHED GATE VALVE BODY 14” Gate Valve 10” Gate Valve

BOUNDARY CONDITIONS PRESSURE LOADING For Both valves, Internal Pressure = 615 Kg/cm 2 Room Temperature = 38 0 C The body is either bolted or welded with the piping system. Hence it is not allowed to move either side. So Flange end portion is fixed with all degrees of freedom.

MATERIAL PROPERTIES The material properties are considered homogenous through out the body. So, the isotropic material properties are considered for the gate valve body analysis, Material= Carbon Steel (WCB) Young’s modulus ‘E’= 2.1E5 N/mm 2 Poisson’s Ration= 0.3 Yield Strength= 248MPa Density= 7850Kg/m 3

14” Gate Valve10” Gate Valve Stress Analysis results for Gate Valve body

Displacement Analysis results for Gate Valve body 14” Gate Valve10” Gate Valve

S.NoBody Maximum Stress MPa Maximum Deformation mm 114” ” RESULT OF BODY ANALYSIS

MESHED GATE VALVE WEDGE 14” Gate Valve 10” Gate Valve

The one side of the wedge meets the fluid pressure, the other side which is just in contact with the valve body, is not allowed to move due to this fluid pressure, so we are arresting the all DOF in the surface, which is just in contact with the valve body. BOUNDARY CONDITIONS PRESSURE LOADING For Both valves, Internal Pressure = 615 Kg/cm 2 Room Temperature = 38 0 C

MATERIAL PROPERTIES The material properties are considered homogenous through out the body. So, the isotropic material properties are considered for the gate valve wedge analysis, Material= Carbon Steel (WCB) Young’s modulus ‘E’= 2.1E5 N/mm 2 Poisson’s Ration= 0.3 Yield Strength= 248 MPa Density= 7850Kg/m 3

Stress Analysis results for Gate Valve Wedge 14” Gate Valve 10” Gate Valve

Displacement Analysis results for Gate Valve Wedge 14” Gate Valve 10” Gate Valve

The 10”3500 and 14”3500 wedge is analyzed by applying above condition, their von misses stress plots and plots, and maximum deformation plots are shown in figure. Neglecting the sharp corners, the valves of maximum stress and deformation are within the allowable limits. S.NoBody Maximum Stress MPa Maximum Deformation mm 114” ” RESULT OF WEDGE ANALYSIS

MESHED GATE VALVE BONNET 14” Gate Valve 10” Gate Valve

The one side of the bonnet meets the fluid pressure, the other side which is just in contact with the bonnet flange, is not allowed to move due to this fluid pressure, so we are arresting the all DOF in the surface, which is just in contact with the bonnet flange. BOUNDARY CONDITIONS PRESSURE LOADING For Both valves, Internal Pressure = 615 Kg/cm 2 Room Temperature = 38 0 C

MATERIAL PROPERTIES The material properties are considered homogenous through out the body. So, the isotropic material properties are considered for the gate valve wedge analysis, Material= Carbon Steel (WCC) Young’s modulus ‘E’= 2.1E5 N/mm 2 Poisson’s Ration= 0.3 Yield Strength= 275 Mpa Density= 7850Kg/m 3

Stress Analysis results for Gate Valve Bonnet 14” Gate Valve 10” Gate Valve

Displacement Analysis results for Gate Valve Bonnet 14” Gate Valve 10” Gate Valve

RESULT OF WEDGE ANALYSIS The 10”3500 and 14”3500 Bonnet is analyzed by applying above condition, their von misses stress plots and plots, and maximum deformation plots are shown in figure. Neglecting the sharp corners, the valves of maximum stress and deformation are within the allowable limits. S.NoWedge Maximum Stress MPa Maximum Deformation Mm 114” ”

Conclusion  By comparing the deformation and stress concentration at various zones of the proven valve and the developed valve,  It clearly shows that the stress and deformation occurs in the developed valve is slightly over than the proven valve.  At the same time it comes below the allowable limits.  This is due to the change of the dimensions and thickness of the developed valve.

 The 14” Gate Valve is successfully running in power plants all over India.  By using the same material, 10”valve is designed.  The Stresses and deformation ranges are also lie below the allowable limits.  So we strongly conclude that the developed 10” Gate Valve is also a Perfect Valve that is suitable for power plant working conditions.

Future Scopes By modifying the dimensions of the developed 10”valve,further we can minimize the stresses and deformation