Submitted to Submitted by Mr.Guravtar Singh Bikramjit Singh Reg. no Roll no. M28T1A11 Design, Solid Modeling and Static analysis on Wedge type Globe Valve using Solid Works and ansys.

CONTENTS Company Profile Certification History Board of directors Valves manufactured by LVL PROJECT  Design of wedge type globe valve  Solid modeling using Solid Works  Static Analysis using Ansys Workbench 10.0

Company Profile Leader valves Ltd. extensive voyage from a traditionally family, to a contemporary solution provider for professionally manufacturing products to impede the leakage of virtually all service fluids & gases, has surely not gone unnoticed. Leader Valves have superlative manufacturing techniques & testing facilities. Each product is made from the finest of material and is subjected to stringent & rigorous checks while being continually inspected by highly qualified personnel at each stage. So much so, that in today’s valves industry, it is not only redefining performance, but also setting the world standard. Company Profile Leader valves Ltd. extensive voyage from a traditionally family, to a contemporary solution provider for professionally manufacturing products to impede the leakage of virtually all service fluids & gases, has surely not gone unnoticed. Leader Valves have superlative manufacturing techniques & testing facilities. Each product is made from the finest of material and is subjected to stringent & rigorous checks while being continually inspected by highly qualified personnel at each stage. So much so, that in today’s valves industry, it is not only redefining performance, but also setting the world standard.

Certifications Leader Valve Limited is an ISO-9001: 2000 company since Jan 1996 certified by LQRA, India. The company is also licensed to use API 600, API BS 1873, API 1868 and API 598. Ferrous & Non-Ferrous foundries are PED certified by M/s. LRQA India & AD 2000-Merkblatt WO certified by TUV India.

HISTORY In the year 1945, a small proprietary firm named “SHAKTI ENGINEERING”. Late Mr. P.N.BERI. It was a humble start with a work force of just 6to 7 people. In the year 1950, the name was changed to “LEADER VALVES LTD.”. Smt. Sarla Beri and her son now occupy this building. Due to further rise in sales and further requirement of valves from both within country and abroad. Now the company have over 1100 dedicated employees with an Annual turn over of Rs. 779 Million. In the year 1945, a small proprietary firm named “SHAKTI ENGINEERING”. Late Mr. P.N.BERI. It was a humble start with a work force of just 6to 7 people. In the year 1950, the name was changed to “LEADER VALVES LTD.”. Smt. Sarla Beri and her son now occupy this building. Due to further rise in sales and further requirement of valves from both within country and abroad. Now the company have over 1100 dedicated employees with an Annual turn over of Rs. 779 Million.

BOARD OF DIRECTORS

Valves manufactured by Leader Valves Limited: 1. GATE VALVES 2. GLOBE VALVES 3. BALL VALVES 4. BUTTERFLY VALVES 5. NON RETURN VALVES 6. AIR RELEASE VALVES 7. DIAPHAGRAM VALVES 8. FLOAT VALVES 9. RELIEF VALVES 10. FOOT VALVES

PROJECT Design, solid modelling and static analysis on Wedge type Globe Valve using Solid Works and ansys. METHODOLOGY VALVE BODY USED FOR ANALYSIS:- 36”-300 WEDGE GLOBE VALVE is used under simulation for finding stresses, strains, deflections and deformation under static and hydraulic loads. PLATFORM USED FOR ANALYSIS:- ANSYS 10.0 WORKBENCH. MODULE USED FOR ANALYSIS :- SIMULATION MODULE. PLATFORM USED FOR DESIGNING :- SOLIDWORKS MATERIAL OF VALVE BODY :- CAST STEEL valve body is used for simulation.

LOADINGS STATIC LOAD :- DUE TO FORCE EXERTED ON BODY BECAUSE OF MOVEMENT OF STEM OR SPINDLE. HYDRAULIC LOAD :- DUE TO PRESSURE EXERTED BY FLUID FLOW ON VALVE BODY.

1.Shell wall thickness tm (300) =0.0334d+4.32 =0.0334* =20.5 Where d= inside diameter or port opening=483mm Stress concentrations = 3mm t= = 23.5mm Hence thickness adopted in drawing = 24mm

As per Indian Boiler Regulation T = (WP*D)/(2f+WP) +C WP= Working pressure of the valve at 425 °C = 28.8 Bar =0.29 Kg/mm2 C= Minimum positive tolerance for cast steel (WCB Gr.) =5mm D= External diameter of chest= 628mm f= allowable stress for grade of material at temperature 425 °C =R/2.7 =Et/1.5 R= Minimum specified tensile strength of the grade of material at room temperature for cast carbon steel =49.22 Kg/ mm 2 for WCB f =Et/1.5 = 49.22/2.7 = 9.85 Kg/ mm 2 Whichever is less

Take 80% of the less value =9.85 Kg/mm2 So, f = 7.88 Kg/mm2 T = (WP*D)/(2f+WP) +C = (0.29*628)/(2* ) +5 = =16.3mm Hence thickness adopted in drawing= 24mm

P t = P o + P c + P f P o = π/4 (d 2 p) =0.786*483*483*0.573 = Pc = 2* π * d o * w * p =2* 3.14* 483* 5* = 8696 P f = π * ds* ls* p* μ =3.14* 110* 180* 0.573* 0.1 =3565 P t = P o + P c + P f = = ) Body / Bonnet joint bolting P b = P n + P t /n Pn = P/n (A+ af * η3) P is the line pressure= 51.1 Bar Seat test pressure =1.1*51.1 = Bar = Kg/m m 2 A= π/4(d 2 ) = π/4(580 2 ) = mm 2 a f = π/4(d1 2 - d2 2 ) = π/4( ) =67675mm 2 η3 = Gasket factor=3.0 Pn = 0.573/n ( * 3) = /n

Stress area of un stud=0.969 sq.inch =625.2 mm 2 Safe load, Pb = (yield strength* stress area)/FOS = (72 * 625.2)/ 2 = No of studs, n = /22507 = 17 Say = 20 NOS Total Load on each stud P b = P n + P t /n = (267840/n) + (117329/n) = /n

4. Design for Yoke sleeve thread engagement L = 2Pt/ π dmfb =2*117329/3.142*97.3*4.22 =182mm. By adopting approximation i.e. =2dm + 6mm =2* = 200 So adopting in drawing = 250mm

5. Torque Required Torque = (P T * P t )/(2 π η ) η = tan α/ tan(α + ϕ ) tan α = P t / π dm =12.7/3.142*97.3 =0.042 Tan ϕ = frictional angle between mating surface of thread =0.24 η =0.042/tan(15.9) =0.042/0.285 =0.147 Torque = (P T * P t )/(2 π η ) = (117329*12.7)/(2*3.142*0.147) = kg mm =1613 kg m =11667 lbs. ft

PARAMETERS USED FOR MODIFICATION: - Ribs and fillets will be applied on the certain zones of body where the deformation resulted out to be more under simulation of the body. With the addition of the fillets and ribs to the areas subjected to extreme stresses and deformations after these modifications the magnitude of stresses and deformation will decrease to certain allowable limit. Shape of wedge should also be modified. To increase its strength, shape of wedge will changed, so that deflection and deformation will be minimised or reduced.

DESIGN OF DIFFERENT COMPONENTS ASSEMBLED TOGETHER IN WEDGE TYPE GLOBE VALVE. Body

Cut Section of Body

Seat and Wedge

Balancing Disc

Complete Assembly

STATIC ANALYSIS OF WEDGE GLOBE VALVE USING ANSYS WORKBENCH 10.0STATIC ANALYSIS OF WEDGE GLOBE VALVE USING ANSYS WORKBENCH 10.0 BODY BEFORE MODIFICATION BODY BEFORE MODIFICATION MATERIAL DATA The following material behavior assumptions apply to this analysis:- Linear - stress is directly proportional to strain. Constant - all properties temperature-independent. Homogeneous - properties do not change throughout the volume of the part. Isotropic - material properties are identical in all directions. TABLE New body.ipt Statistics Bounding Box Dimensions 0.86m 0.75m 0.69 m Part Mass kg Part Volume 7.11 ×10 -2 m³ Mesh Relevance Setting 0 Nodes Elements 28998

FIGURE 1FIGURE 1MESHING

MAXIMUM SHEAR STRESSMAXIMUM SHEAR STRESS FIGURE 2FIGURE 2

TOTAL DEFORMATIONTOTAL DEFORMATION FIGURE 3FIGURE 3

FIGURE 4FIGURE 4 DIRECTIONAL DEFORMATIONDIRECTIONAL DEFORMATION

Bounding Box Dimensions 0.86m 0.75m 0.69m Part Mass Kg Part Volume 7.94×10 -2 m³ Mesh Relevance Setting 0 Nodes Elements TABLE New body.ipt Statistics NameMinimumMaximum Equivalent Stress Pa70, Pa Maximum Shear Stress Pa37, Pa Total Deformation 0.0 m1.63×10 -7 m Structural Results

Body before modificationBody after modification Maximum Equivalent stress =75, pa Maximum Equivalent stress= 70, Pa Maximum Shear stress=35, pa Maximum Shear stress= 37, Pa Minimum Principal stress=11,36 7 paMinimum Principal stress=17,214 pa Safety Factor=11Safety Factor=15 Maximum Deformation=1.23 × m Maximum Deformation= 1.63×10 -7 m CONCLUSION Comparing the result of body before modification and body after modification THEREFORE, COMPARING WITH THE RESULTS OF VALVE BODY BEFORE MODIFICATION WE CAN CLEARLY FOUND THAT VALUES OF STRESSES AND DEFORMATION HAS DECREASED TO GREAT AMOUNT AFTER CERTAIN MODIFICATIONS IN THE VALVE BODY AND EMPLOYING C.A.E TECHNOLOGY.