Design of A Large Cut Off Valve - Final Report

SCHOOL OF ENGINEERING DEPARTMENT OF MECHANICAL AND AERONAUTICAL ENGINEERING DESIGN OF A LARGE CUT OFF VALVE
Compiled by: MR. D.D. JONKER, 28511141 STUDY LEADER: PROF. N.J. THERON
Submitted in Partial Fulfilment of the requirements of the Degree Baccalaureus Engineering (BEng: Mechanical Engineering) Faculty of Engineering, Built Environment, and Information Technology of the University of Pretoria
04 JUNE 2012
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D. D. Jonker 28511141 Design MOX_410 Prof. N. J. Theron 04 June 2012
Report
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Abstract
Title: Author: Student Number: Study Leader: Design of a large cut-off valve D. D. Jonker 28511141 Prof. N. J. Theron
The purpose of the project is to design a large cut-off valve to be used to isolate turbines in hydroelectric power plant. The valve is to be used in conjunction with a 10MW water turbine operating under a 30m water head. The valve is designed and adapted for South African conditions in terms of manufacturability, affordability in comparison with commercially available cut-off valves. The large sized valves are usually not mass produced but custom made for each specific operational conditions. A detailed literature study was conducted in order to familiarise the designer with cut-off valves and their operations. It was found that four basic cut-off valves; (1) butterfly valve, (2) cone valve, (3) gate valve, and (4) spherical valve, are common in the hydropower plants. The selection of these valves is generally based on the available head of hydropower plant and the desired amount of electric power that should be generated. From the knowledge acquired from literature study, together with the requirements provided by the client, the design specifications were compiled. Different concepts for each of the subsystems were generated and evaluated, and the best concepts were selected and modified accordingly. Designs of most of the components were based upon worst case scenarios for a more conservative approach. All calculations were referenced accordingly for easy to follow methods. Since the product was assumed to be a new platform in the market, cost analysis of the whole system is highly estimated in order to come up with a whole figure of cost. The necessary detailed drawings and specifications of manufacturing processes are provided for most of the components. The valve design is practical and can find other application in similar industry to hydropower such as mines, although no simulations of the flow through the valve were conducted. The system components are simple enough for purposes of manufacturability, as this aspect is important.
Keywords: cut-off valve, hydroelectric power plant, manufacturability, butterfly valve, new platform
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Acknowledgements
I would like to thank my family for their continuing support and encouragement throughout my study period, especially during this academic year. Special thanks go to my colleague for their assistance, my friends for their contribution and any other persons that may have touched my life positively. I wish to express my sincerest gratitude to the following people for their valuable input and guidance throughout my study period at UP, although some may have left: Prof. N.J. Theron: Study Leader whose guidance, encouragement, and support were immeasurable during the hard times of the semester. Design Lecturer Design Lecturer Design Lecturer Drawing Instructor
Dr S. Kaul Mr. P.R. De Wet Prof. N.D.L. Burger Mr. Plomp
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Table Contents
Abstract .................................................................................................................................................... i Acknowledgements................................................................................................................................. ii List of Figures .......................................................................................................................................... v List of Tables ......................................................................................................................................... vii List of Symbols ..................................................................................................................................... viii 1. Introduction .................................................................................................................................. 10 2. User Requirements ....................................................................................................................... 11 3. Mission Statement ........................................................................................................................ 12 4. Literature Study ............................................................................................................................ 13 4.1. Hydropower Engineering ...................................................................................................... 13 4.1.1. The history of Hydropower ........................................................................................... 13 4.1.2. The Potential of Hydropower........................................................................................ 14 4.1.3. Components of Hydropower Plant ............................................................................... 15 4.2. Valves .................................................................................................................................... 18 4.2.1. Major Valve Applications in Hydropower ..................................................................... 18 4.2.2. Cut Off Valves Functions in Hydropower Plant ............................................................. 19 4.2.3. Current Cut-off Valve Used in Penstock of Hydroelectric Power Plants....................... 20 4.3. Power Calculations from Water ............................................................................................ 24 4.4. Literature Study Conclusion .................................................................................................. 25 5. Functional Analysis........................................................................................................................ 26 5.1. System Level Diagram ........................................................................................................... 26 5.2. Mission Level Diagram .......................................................................................................... 27 5.3. System level function diagram .............................................................................................. 28 5.4. First level functional diagram................................................................................................ 29 6. Design Requirements .................................................................................................................... 30 7. Concept generation ...................................................................................................................... 31 7.1. Concept evaluation and selection......................................................................................... 34 7.1.1. Concept rating and selection ........................................................................................ 34 7.1.2. Concepts Modification .................................................................................................. 37 8. Detail Design ................................................................................................................................. 39 8.1. Penstock pressure ................................................................................................................. 39 8.2. Valve Housing........................................................................................................................ 40 8.2.1. Valve Flow Rate ............................................................................................................. 40 8.2.2. Internal Valve Diameter ................................................................................................ 40 8.2.3. Valve shell thickness ..................................................................................................... 41 8.2.4. Valve End Connection ................................................................................................... 44 8.3. Minimum Disc Thickness....................................................................................................... 48 8.4. Load Analysis of Shaft ........................................................................................................... 50 8.4.1. Shear Force and Bending Moment ............................................................................... 51 8.4.2. Shaft Strength and Life Expectancy .............................................................................. 53 8.5. Bearing Selection .................................................................................................................. 55 8.5.1. Application Assessment ................................................................................................ 55 8.6. Seals Selection....................................................................................................................... 56 8.6.1. Shaft seals ..................................................................................................................... 56 iii | P a g e Design of a large cut-off valve
MOX_410 [JUNE 2012] 8.6.2. Disc Seat ........................................................................................................................ 57 8.7. Valve torque and Actuator Sizing.......................................................................................... 58 8.7.1. Valve torque analysis .................................................................................................... 58 8.7.2. Torque components ...................................................................................................... 60 8.7.3. Torque Unit ................................................................................................................... 60 8.7.4. Actuator sizing............................................................................................................... 63 9. Design Analysis.............................................................................................................................. 65 9.1. Manufacturing Analysis ........................................................................................................ 65 9.1.1. Valve shaft manufacturing process............................................................................... 65 9.1.2. Valve body manufacturing process............................................................................... 68 9.1.3. Manufacturing processes for the whole product ......................................................... 70 9.2. Maintenance Analysis ........................................................................................................... 71 9.2.1. Component failure ........................................................................................................ 71 9.2.2. Protection from the environment................................................................................. 71 9.2.3. Protection of human lives ............................................................................................. 71 9.3. Reliability analysis ................................................................................................................. 72 9.4. Cost Analysis ......................................................................................................................... 72 10. Conclusions and Recommendations ......................................................................................... 74 10.1. Conclusions ....................................................................................................................... 74 10.2. Recommendations ............................................................................................................ 74 11. References ................................................................................................................................ 75 12. Annexure ................................................................................................................................... 77 12.1. Appendix A: Final models of the cut-off ........................................................................... 77 12.2. Appendix B: Simulations using computer software .......................................................... 79 Simulation of the valve disc .............................................................................................................. 79 12.3. Appendix C: Detailed drawings ......................................................................................... 81
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List of Figures
Figure 1: Installations of large cut-off valves at Draper water treatment plant [1] ............................. 10 Figure 2: Oxygen cutting torch and hot rolling material fabrication (Ball et al, 2002) ......................... 10 Figure 3: Maximum power output of selected power devices over the period 1700-1970................. 13 Figure 4: Schematic diagram of a typical hydropower plan ................................................................. 15 Figure 5: Actual plan of hydropower plant (the world bank group, 2009) ........................................... 15 Figure 6: Existing Katsu river dam in Lesotho (Woltz, 2011) ................................................................ 16 Figure 7: Typical layout of penstock assembly ..................................................................................... 18 Figure 8: Model of gate valve used in piping industry (DeZurik Inc, 2011) .......................................... 20 Figure 9: Models of manual and actuator controlled butterfly valves (Valmatic, 2010)...................... 21 Figure 10: Model of a spherical valve (DeZurik Inc, 2011).................................................................... 22 Figure 11: Model of cone valve (DeZurik Inc, 2011) ............................................................................. 24 Figure 12: System level diagram ........................................................................................................... 26 Figure 13: Mission level diagram .......................................................................................................... 27 Figure 14: System level functional diagram .......................................................................................... 28 Figure 15: First level functional diagram .............................................................................................. 29 Figure 16: final model of the main valve body ..................................................................................... 37 Figure 17: final model of the torque unit ............................................................................................. 37 Figure 18: final model of the support structure ................................................................................... 38 Figure 19: Final assembly of the product.............................................................................................. 38 Figure 20: Maximum head of hydropower plant .................................................................................. 39 Figure 21: Pressurised valve shell ......................................................................................................... 42 Figure 22: Most common flanged end connection for valve ................................................................ 44 Figure 23: forged steel flanges specifications ....................................................................................... 45 Figure 24: valve - penstock bolt connection ......................................................................................... 46 Figure 25: Disc held in position by shaft and seat shoulder ................................................................. 48 Figure 26: Symmetrical bending caused by the uniform loading ......................................................... 48 Figure 27: actual deflection of the valve disc ....................................................................................... 49 Figure 28: Typical assembly of the valve shaft and disc ....................................................................... 50 Figure 29: Pressure loading on the disc ................................................................................................ 50 Figure 30: Reaction forces on the shaft ................................................................................................ 51 Figure 31: Shear force diagrams in y-z and x-z planes .......................................................................... 52 Figure 32: Bending moment diagrams in both y-z and x-z planes ........................................................ 52 Figure 33: single PTFE V-Ring packing for sealing the shaft.................................................................. 57 Figure 34: Arrangement of the disc seal ............................................................................................... 57 Figure 35: Bearing torque on the shaft ................................................................................................. 58 Figure 36: centre of gravity torque ....................................................................................................... 59 Figure 37: Torque unit .......................................................................................................................... 61 Figure 38: forces on the screw and the caller caused by torque .......................................................... 61 Figure 39: TMW torque motor.............................................................................................................. 63 Figure 40: Valve shaft with differing diameters and connection holes ................................................ 65 Figure 42: Diameter reduction of the shaft .......................................................................................... 66 Figure 41: typical shaft manufacturing processes ................................................................................ 66 v|Page Design of a large cut-off valve
MOX_410 [JUNE 2012] Figure 43: Chamfering of the shaft ends .............................................................................................. 67 Figure 44: oxygen cutting of plates into desired lengths ...................................................................... 68 Figure 45: a holed plate segment for bearing housing connection ...................................................... 68 Figure 46: tube forming of the plate segments .................................................................................... 69 Figure 47: workshop fabrication of large diameter cylinders [22] ....................................................... 69 Figure 48: Final model in closed position ............................................................................................. 77 Figure 49: Final model on an opened position ..................................................................................... 77 Figure 50: Final model in a 45 degree open position............................................................................ 78 Figure 51: Valve disc with support bars welded onto the disc ............................................................. 79 Figure 52: Deflection of plane valve disc .............................................................................................. 80 Figure 53: Deflection of a valve disc with support bars ........................................................................ 80
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List of Tables
Table 1: Mission statement of a large cut-off valve ............................................................................. 12 Table 2: Unexploited hydropower potential as a percent of total potential amounts ........................ 14 Table 3: hydropower potential in South Africa in 2002 (Klunne, 2012) ............................................... 14 Table 4: Advantages and applications of Gate valve ............................................................................ 21 Table 5: Advantages and applications of butterfly valves .................................................................... 22 Table 6: Advantages and applications for Spherical valves .................................................................. 23 Table 7: Advantages and applications for Cone valves ......................................................................... 23 Table 8: design requirements ............................................................................................................... 30 Table 9: Concept generation for the main valve .................................................................................. 31 Table 10: Concept generation for torque unit ...................................................................................... 32 Table 11: Concept generation for support structure ............................................................................ 33 Table 12: Concept rating ....................................................................................................................... 34 Table 13: Valve type concept evaluation matrix................................................................................... 34 Table 14: Torque unit concept evaluation matrix................................................................................. 35 Table 15: Support structure concept evaluation matrix ....................................................................... 36 Table 16: Given Information of hydropower plant ............................................................................... 40 Table 17: Extrapolation method ........................................................................................................... 45 Table 18: Calculated flange specifications in millimetres and kilograms ............................................. 45 Table 19: valve disc simulation results ................................................................................................. 49 Table 20: Summary of bush dimensions, clearances and tolerances ................................................... 56 Table 21: manufacturing schedule for valve shaft................................................................................ 67 Table 22: manufacturing processes ...................................................................................................... 70 Table 23: final product cost estimates .................................................................................................. 73
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List of Symbols
symbol C H, P, Q z g V t D, d , , , K NB, ND l L E N T h W Definition Optimal pipe diameter Constant, stiffness constant Head Net power output, pressure Flow rate/discharge rate Overall plant efficiency Turbine efficiecy Electrical system efficiency Generator efficiency Civil work efficiency Specific weight Maximum head gravity Flow velocity Wall thickness Valve diameter, bolt diameter Longitudinal stress Hoop stress Shear stress Von mises stress Amplitude stress components, principal stress Endurance limit Ultimate tensile stress Class thickness coefficient, constant Nominal diameter Grip length, lead Bolt length Thread length Unthreaded portion of grip length Threaded portion of grip length Nominal diameter Major diameter, disk area Bolt stiffness Youngs modulus Member stiffness Bolt load Member load Preload force Number of bolts Safety factor, load factor torque Gasket area Resultant force of member Poissons ratio Yield strenght Disk diameter density weight viii | P a g e Design of a large cut-off valve
MOX_410 [JUNE 2012] M Distributed loading Surface factor Size factor Loading factor Temperature factor Reliability factor Miscellaneous factor Stress concentration factor Bending moment Fatigue safety factor
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1. Introduction
Selection of piping system is an important aspect of system design in any energy consuming system such as hydroelectric power plant. The selection factors such as material of pipe, configuration, diameter, etc have their own impact on the overall energy consumption of the system. In hydropower facility, the conduits are ordinarily provided with cut-off devices, except in large low head plants. These devices exist in different design and types depending on specific function and requirements. In any power plant valves, normally cut-off valves are installed just in front of the turbine. The cut-off valves facilitate emptying of turbines without emptying the conduits and they also form part of the safety systems of the plant by protecting equipment and human lives, in an eventual rupture of conduit. Cut-off valves are usually operated by a fully independent system.
Figure 1: Installations of large cut-off valves at Draper water treatment plant [1]
The choice of pipe diameter depends on the required flow rate and determines the diameters of the pipe accessories such as the different valves used as safety systems. Large diameter cut-off valves are not readily available in South Africa and are generally manufactured per order. In this report, a design of a cut-off valve to be used particularly in hydropower plants is introduced with adaptation for the countrys conditions. The project requirements states that the manufacturability of the valve should be at the forefront of the design in terms of South African facilities or workshops. Due to the size of the valve, different methods for fabrication will be stated with regard to availability of workshops.
Figure 2: Oxygen cutting torch and hot rolling material fabrication (Ball et al, 2002)
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2. User Requirements
Large cut-off valves are usually not mass produced but specially designed and manufactured for each particular application. The cut-off valves will be permanently mounted on the penstock to isolated turbines in hydroelectric power stations. The client provided the following requirements: The valve should be compatible with a 10MW turbine operating under a 30m water head. Thus the design variable, valve diameter, should be large enough for the turbines to operate at optimal level. The valve should be connected to the penstock by two flanged couplings for ease of attachment. The water flow speed through the valve should not exceed 9 /. The operator should be able to fully shut the valve from fully open position in under 1 . During operational condition, the valve should not apply static or dynamic loading on the inlet and outlet as specified by the client with the exception of the self equilibrating loads. The manufacturability of the valve components with regard to South African facilities or workshops would be preferable. The designer should specify the packing to be used and clearances between flanges before tightening of the bolts. Exceptions to user requirements Water hammer effects need not be taken into account in any way other than the effect of water hammer on piping, since cut-off valves are never used to completely stop water flow from maximum flow speed. The designer should not consider thermal expansion of piping with regard to axial loading limits.
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3. Mission Statement
The mission statement summarises the direction to be followed by the designer. It describe amongst others, the importance of the system (product), assumptions, and stakeholders. It is displayed in the table format below:
Table 1: Mission statement of a large cut-off valve
Product description
Large cut-off valve to isolate 10MW turbines in hydroelectric power plants Cut off water flow in case of emergency and/or during maintenance. Form part of the plant safety system Use independent power source Reduce manufacturing cost Serves as platform for all future power plants Hydroelectric power station Fluid piping system industries (fuel, water drainage, floods control, waste water management, etc) New product in local market Improvement on the present product platform Users/Customer Machine Operators Hydropower industry groups Manufacturers Product suppliers
Benefit proposition
Key business goals
markets
Assumptions and constraints
stakeholders
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4. Literature Study
A literature study was performed on relevant aspects to the design project. It is divided into multiple subsections and widens the understanding of the subject in applications of large cut-off valves, design of valves, major components of valves, as well as disadvantages of commercially available cut-off valves.
4.1.
Hydropower Engineering
4.1.1. The history of Hydropower Continuous flowing or falling water has been used for many centuries to perform work, the particular uses varying with the political and social conditions of the times. It is believed that the Greeks and Romans were among the first to take advantage of the power provided by flowing water. These nations used a waterwheel, which was placed vertically along a stream or river, for grinding corn with its gears, thus operating the mill. Other earlier tasks included irrigation, sawing wood, power textile mills and later operating manufacturing plants, although the mills or factories had to be located at the hydropower sites for ease of utilising the available energy readily. These earlier plants usually had limited power output of anything around 100 kW (Gulliver & Arndt, 1991).
Figure 3: Maximum power output of selected power devices over the period 1700-1970.
In the 19th century, hydropower became a source of electrical energy as the water turbine technology gradually replaced the waterwheel due to the turbines higher efficiency. The generation of electrical energy from flowing water increased the necessity of larger hydropower plants because the generated energy no longer needed to be used on sites.
MOX_410 [JUNE 2012] 4.1.2. The Potential of Hydropower Hydropower represents the largest (more than 90 percent) of all resources of renewable energy generated and still proves to be relevant energy resource for current and future generations. The considerable potential, planned or remaining in the developing regions/continents such as Asia, Africa, and South America is out in the open and amounts to approximately half the worlds total hydropower potential according to a study on hydropower and dams world atlas 2008 by the AquaMedia international. The total economically feasible potential hydropower capacity in developing countries exceeds 1900 GW and about 70 percent of which is not yet exploited. On a regional basis, unexploited potential as a percent of total potential amounts to:
Table 2: Unexploited hydropower potential as a percent of total potential amounts
Region Africa East and the Pacific Middle East and North Africa Europe and Central Asia South Asia Latin America and the Caribbean
Total Potential Percentage 93 percent 82 percent 79 percent 78 percent 75 percent 62 percent
The potential of hydropower in South Africa is limited by the amount of rainfall, averaging 500 mm, which is low by world standards. The countrys potential is also concentrated in a few areas along the eastern regions where the number of potential sites is reported to be around 6,000 to 8,000 (Klunne, 2012). The reflection of the overall assessment of the hydropower types in South Africa is given in table-3. In the past, the theoretical hydropower potential in South Africa was estimated to be about 8360 MW (54925 GWh per annum at 75 percent loading). From the table below, it is estimated to be over 12000 MW, which is 45 percent higher than the previous estimates.
Table 3: hydropower potential in South Africa in 2002 (Klunne, 2012)
Category
size
Installed capacity (MW) 0.02 0.1 8.1 25.7 653 1580 800 3060
Potential for development Firmly established (MW) 0.1 0.4 5.5 63 5090 7000 1400 13560 Additional long term (MW) 60.2 3.8 5 25 1900 3200 >55000 -
Pico Micro Mini Small Conventional macro Pumped storage macro Imported macro Total
Up to 20 kW 20-100 kW 100-1000 kW 1-10 MW >10 MW >10 MW >10 MW
MOX_410 [JUNE 2012] 4.1.3. Components of Hydropower Plant The arrangement of hydropower plants is dependent on the initial available information concerning the site area. This includes a collection of information on topography, geology, soil maps, and aerial photography. One of the prominent features of a hydropower plant is the variety of configurations that exist. The different types of plants allow the planners as well as engineers to meet the specific requirements for the chosen sites. Of course, this may be seen as an additional burden on engineers to arrive at an estimate of feasibility, since several different configurations should be studied. The layout of a typical hydropower plant and description of some major components are given in figures -4 and -5.
Figure 4: Schematic diagram of a typical hydropower plan
Figure 5: Actual plan of hydropower plant (the world bank group, 2009)
4.1.3.1.
Dam and Reservoir
Reservoir is a basic requirement of a hydropower plant and it is where large quantity of water is stored, especially during flood season and can be used during dry season. A dam is a barrier structure built across a water course for impounding water, thus creating a reservoir. The function of a dam is to increase the height of water level which in turn increases the reservoir capacity. Dams may be classified as follows: a. Masonry and rubble dams: Any dam built mainly of stone, brick, or concrete blocks jointed with mortar (masonry) or unshaped stones (rubble). b. Embankment dams: Any dam built from excavated materials or industrial waste materials. c. Concrete dams: Any dam constructed from reinforced or unreinforced concrete. d. Roller-compacted concrete dams: Any dam constructed of no-slump consistency that is compacted with vibratory rollers.
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Figure 6: Existing Katsu river dam in Lesotho (Woltz, 2011)
4.1.3.2.
Powerhouse and its foundation
The powerhouse is located at the end of the waterway and as low as possible below the elevation of the dam and/or reservoir. Thus, allowing maximum available head for the turbine. Other considerable factors which may affect the powerhouse location include foundation conditions, valley width, accessibility and tail-water elevation. The function of powerhouse is to provide support and housing for the turbine-generator unit and all auxiliary equipments. Its arrangement is dependent upon the type of turbine-generator selected and can be divided into three main areas: the main powerhouse structure, generator units housing, erection bay and service areas. General types of powerhouse in existence are: a. Indoor type: The generator room is fully enclosed and is of sufficient height to permit transfer of equipment by means of an indoor crane. b. Semi-outdoor type: the generator floor is fully enclosed but the equipment is handled by an outdoor gantry crane or mobile crane through hatches in the roof. c. Outdoor type: There is no generator room; instead the generators are housed in individual cubicles or enclosures on deck. d. Underground type: This type is usually associated with large hydrogenation units and pumped storage units. The rock shell is formed by the excavation from the walls and roof of the powerhouse. The selection of the powerhouse is made on the basis of an economic analysis which considers costs, operation as well as maintenance. It is highly recommended that powerhouse selection, for any given site, be made after thorough study (Gedeon, 1995). 4.1.3.3. Turbine-Generator Unit
The turbine and generator are the primary electrical and mechanical components of a hydropower plant. A turbine converts water energy into the mechanical energy of the turbine shaft, which drives a generator to produce electrical energy. There are two main categories of turbines, viz. reaction (francis and Kaplan) and impulse (pelton). The impulse turbine converts the available head into
MOX_410 [JUNE 2012] kinetic energy before entering the runner, while the available power from the water flow is extracted at atmospheric pressure. In case of reaction turbine, the runner is fully submerged and both the pressure and velocity decrease from inlet to outlet. The velocity head at the inlet to turbine runner is usually less than 50 percent of the total head available. The type of turbine depends on the available head of the water stream: a. For low to medium head applications, reaction turbines are used. b. For high head applications, impulse turbines are generally used. 4.1.3.4. Penstock
A penstock generally refers to a steel conduit or steel-lined tunnel that conveys the water from the dam or reservoir to the turbine (Gulliver, and Arndt, 1991). The penstock should be hydraulically efficient as practical to conserve available head and structurally safe to prevent failure which would result in loss of life and property. They can be built from many materials, but the strength and flexibility of steel make it best suited for the range of pressure fluctuations met in turbine operation. The economical diameter of the penstock is determined by the minimum combined construction costs, maintenance costs and energy reduction caused by head loss. The following variables are usually considered when selecting a penstock: a) b) c) d) e) f) g) h) i) Cost of pipe Value of energy loss Minor loss factor Average head Water-hammer effect Weight of steel Surface roughness Design discharge Allowable hoop stress
For the assessment of a preliminary penstock design or a feasible level, the optimum diameter can be estimated using the following empirical equations which are not necessarily specific to the conditions present at site. The following equation was developed by Moffar and colleagues. For large hydropower plants, the constant C equals 0.71 and small plants C equals 0.52 (Coleman, et al, 2004). = . 10 .
Fahlbusch analysed few hundred conduits for conventional hydropower plants and for steel-lined conduits, he found that the economical diameter could be expressed as (Gulliver, and Arndt, 1991): 1.12 = .
.
20
For small plants, the following simple equation can be used (Coleman, et al, 2004):
MOX_410 [JUNE 2012] = 0.72 . 20 A typical penstock layout is given in figure xxx showing the major components of the assembly. The length of the penstock is highly variable, ranging from non-existence for low head hydropower plants to several kilometres down the side of a mountain in large plants.
Figure 7: Typical layout of penstock assembly
4.2.
Valves
A valve, by definition, is a mechanical closure device in which the closure member remains fixed axially with respect to the fluid way and is either rotated or moved longitudinally to regulate the fluid flow. Valves are generally used in piping systems and their functions includes isolation of system equipments, switching on/off and controlling fluid flow, emergence cut-off, amongst others. Large valve can be operated manually with a lever and gear operators or remotely with electric, pneumatic, electro-pneumatic and electro-hydraulic powered actuators to supply force and motion to open and close depending on the frequency of operation and/or the availability of the power source. 4.2.1. Major Valve Applications in Hydropower There are different applications of valves in hydropower plants and in order to clarify the scope of the design, it is necessary to describe the different types of major valves used. Based on the functions and services that valves provide, valves used in hydropower plant are categorised as follows:
MOX_410 [JUNE 2012] 4.2.1.1. Cut-off Valves
Cut off valves are usually installed at the downstream of the penstock near the inlet of turbine case. Their primary function is to cut off water supply to the turbine, thus allowing turbine dewatering for inspection and maintenance without emptying the penstock. The turbine inlet valve is also used to cut off water flow and stop the turbine-generator unit when the wicket gates fail to close particularly during an emergency situation of load rejection and wicket gate malfunction. The most commonly used valves include butterfly valves, cone valves and spherical valves. For head up to 120 meters, the butterfly valves are highly recommended. Spherical valves are used for heads up to 1200 meters and cone valves can be used for up to 1800 meters head. 4.2.1.2. Flow Control Valves
Large water penstock requires flow control valves to regulate the flow of water to the runner, especially in impulse type hydropower turbines. These types of valves work together with fixed cone dispersion and hollow jet valves which are used to control releases from low level outlets, sleeve valves which control flow in in-line piping systems, as well as energy dissipating valves. 4.2.1.3. Energy Dissipating Valves
Efficient energy dissipating valves were developed to improve the operating characteristics and lessen stringent stilling basing requirements as water may be released from a reservoir through low level outlets for reservoir level control, downstream water demands, or minimum stream flow requirements. Fixed cone dispersion valves are often use for controlling free discharge for heads up to 300 meters and sleeve valves for dissipating heads in closed systems without cavitation damages. 4.2.1.4. Air or Vacuum Valves
Air valves are provided in piping systems to exhaust air from penstock system or spiral case, and/or to fill a vacuum to prevent conduit collapse. 4.2.1.5. Pressure Control Valves
These types of valves are used as safety devices on air pressure tanks and on governor pressure set accumulators. They are used to provide a regulated pressure source (normally constant pressure) of air, oil, or water in hydro facilities, by reducing their opening as upstream pressure rises. The pressure regulator valve is applied for transient control which opens to discharge the penstock flow simultaneously with quick wicket gate closure. Pressure valves allow the penstock flow to remain relatively constant during the load rejection. 4.2.2. Cut Off Valves Functions in Hydropower Plant Cut off valves form part of the hydropower safety system whose objective is to protect the plant equipment, and the environment from damage in case of failure of malfunction. Safety systems are prerequisites in hydropower to minimise production losses by avoiding secondary damages to equipment as well as to protect personnel. The roles played by cut off valves are as follows:
MOX_410 [JUNE 2012] Stops and decreased water entry during turbine stoppage in order to protect the guide vanes against silt cavitation and silt erosion. Stops the water entry in case of emergency, that is, non-closure of guide apparatus or in the event of low oil pressure in the system. Unit isolation in multi-unit plants where one penstock feeds more than one unit. Facilitate inspection of water path passages. 4.2.3. Current Cut-off Valve Used in Penstock of Hydroelectric Power Plants In hydropower plants, the widely used valves for cut off valves are butterfly valve type, cone valve type, gate valve type or spherical valve type depending on the head at the turbine inlet. It is good practice to select a valve type that incorporate arrangements for slow filing of turbine casing by either crack opening or by special bypasses. Different commercially available valve models shown in the figures below are discussed. 4.2.3.1. Gate Valve
Gate valves are by far the most widely used valve type in industrial piping. Gate valves are an ideal isolation valve for high pressure drop and high temperature applications where operation is infrequent. They have a sliding disc that reciprocates into and out of the valve port and manual operation is accomplished through a multi-turn hand wheel gear shaft assembly. An ordinary design of a gate valve is mostly produced with cast housing, however for lower heads some are produced with a welded housing. The working principle of the gate valve is move the gate over the valve seat in the closed position, and withdraws the gate from the seat in the open position using an actuator or a hand wheel.
Figure 8: Model of gate valve used in piping industry (DeZurik Inc, 2011)
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Table 4: Advantages and applications of Gate valve
Recommended use Fully open/closed, non-throttling Infrequent operation Minimal fluid restriction Tight shut off and long service Advantages High capacity Tight shutoff Low cost Little resistance
Applications in relation to hydropower Diameters up to 750 mm
Disadvantages Poor control Cavitate at low pressure drops Cannot be used for throttling
4.2.3.2.
Butterfly Valve
Butterfly valves are normally applied in front of low and medium head water turbines. This type of valves use disc that rotates 90 degrees to open and close the valve. Reliability and performance related components of a butterfly valve consist of the valve body, valve seal, disc, and torque unit. The valve body is a cylindrical ring of the same diameter as the connecting pipeline. It houses the disc and has flanged ends for attachment to the piping system. The valve seat is usually made of flexible material such as rubber, nylon, or metals like bronze or stainless steel. Its purpose is to prevent leakage through the valve when in closed position. In larger, high performance valves, the seat is normally offset from the shaft in order to avoid being penetrated by the shaft. The disc is usually made of ductile iron for added strength and smaller cross section designs. Its main function is controlling the amount of water flow through the valve. The butterfly disc introduces head loss in the valve as it is always present in the flow.
Figure 9: Models of manual and actuator controlled butterfly valves (Valmatic, 2010)
MOX_410 [JUNE 2012]

Table 5: Advantages and applications of butterfly valves
Recommended use Fully open/closed, or throttling frequent operation Advantages High capacity Low pressure drop Low cost and maintenance Good flow control
Applications in relation to hydropower heads up to 200 m Disadvantages High control torque requirements Cavitate at lower flows
4.2.3.3.
Spherical Valve
The spherical valves are applied as cut-off valves in front of high head water turbines. This type of valve consists of three main elements: The valve body which is usually cast in four pieces (two body halves and two adapters) and houses the ball sub-assembly. The adapters carry the body seats and also function as heavy flanges for attachment of the valve to the pipeline. The ball is shaped like two intersecting cylinders, one being the full ported waterway and the other retaining the seats. It rotates on support trunnions, normally integrally cast with the ball for optimal body rigidity and has a short shaft which connects with one of the trunnions and extends through the valve body to the torque unit. The ball is the part that controls flow through the valve. Torque unit is the valve operating mechanism which rotates the ball as valve opens or closes. The unit is attached to the ball by a shaft and usually provides variable rotation speed to minimise surge and water hammer. The working principle of the spherical valve is that when the valve is opened, the ball is rotated such that the hole through the ball is in line/parallel with the valve body inlet and outlet or flow direction. When closed, the ball rotates such that the hole is perpendicular to the flow openings of the valve and the flow is cut off. The valve body assembly is accomplished with O-rings to prevent leakage.
Figure 10: Model of a spherical valve (DeZurik Inc, 2011)
MOX_410 [JUNE 2012]

Table 6: Advantages and applications for Spherical valves
Recommended use Fully open/closed, Limited throttling High temperature fluids Tight shut off and long service Advantages High capacity Tight sealing with low torque Low cost Minimal fluid restriction
Applications in relation to hydropower Used for critical cut-off services for head ranging from 160-1250 m, although they can be used for lower heads as well Disadvantages Poor throttling characteristics Cavitate at low pressure drops
4.2.3.4.
Cone Valve
Cone valves are similar to spherical valves as they have a conical plug containing a full bore passage which controls the flow. Cone valve consists of four main elements: Valve body is normally a cast of iron or steel with weld-overlaid seats around the bore and its function is to house the plug and attach the valve to the piping system. The plug is also a cast in the shaped of a frustum of a cone. It has a bore passage with two pairs of seats; one pair mates to the body in the fully open position, while the other pair mates in the closed position. The valve cover encloses the plug in the valve body and support the operating mechanism. The cover has a hole through which the shaft connecting the plug and operating mechanism passes. The valve operating mechanism is usually mounted on the head cover. The mechanism comprises lift-and-lower nut for lifting and lowering of the plug and rotator lever for rotation necessary to open and close the plug. The working principle of the cone valve from closed position is first, lift the plug axially without rotation to separate the plug seats from the valve body seats, then smoothly rotate the plug 90 degrees and finally, axially lower to reseat the plug to create a full port unrestricted waterway. This operation offers positive protection of the seats at all times and thus, guaranteeing longer, maintenance free service.
Table 7: Advantages and applications for Cone valves
Recommended use Fully open/closed, limited throttling Advantages Long life Low maintenance Minimal fluid restriction High capacity
Applications in relation to hydropower Head > Disadvantages Poor throttling characteristics
MOX_410 [JUNE 2012]
Figure 11: Model of cone valve (DeZurik Inc, 2011)
4.3.
Power Calculations from Water
A hydropower plant requires water flow and a drop in height (head) to produce useful power. The plant can be considered as a power conversion system, absorbing power in the form of head and flow, and delivering power as electricity or mechanical shaft power. It is a known fact that no power conversion system can transfer as much useful power as it absorbs. Some of the power is lost by the plant itself in the form of friction, heating, noise etc. The net power output of a hydropower plant is given by the equation (Harvey, 2011): = Watts Where: P Q = Generated power output = Overall plant efficiency = Turbine discharge/flow rate
= Gross head on turbine-generator unit The actual electric power delivered by the hydropower plant is lower than the theoretical power due to the inefficiency of the hydraulic conveyance system. The overall efficiency of a typical hydro scheme is expressed as (Harvey, 2011): = Where:
MOX_410 [JUNE 2012] is the efficiency of the turbine which is about 0.85 depending on the turbine manufacturer. For pumps used as turbines and locally-built cross flow turbines, the value of ranges from 0.6-0.8 and 0.5-0.7 respectively. is the generator efficiency and is usually more than 0.9
is the efficiency of the rest of the electrical system which is usually more than 0.95. However, this value could be lower if long transmission power lines are used. is the efficiency of civil works which includes the penstock or conduits and water channels and its value is usually more than 0.9.
4.4.
Literature Study Conclusion
The literature review included an investigation of different components of hydropower station, applications of valves used hydropower station, and the common valves used as cut-off valve. The operations of these valves were also investigated to assist in understanding the main purposes of cut-off valve. A wide range of literature through the internet, library books, journals, catalogues, etc were referred during the conduction of this review. This study suggested that large cut-off are not available for comparison of the manufacturing and purchasing cost, unless an order of such a cut-off valve is placed in the more established valve manufacturing companies. This fact will represent a hurdle when the manufacturing cost of the current design is analysed.
MOX_410 [JUNE 2012]
5. Functional Analysis
Functional analysis helps to convey information and ensures that all possible functions will be considered when designing the system. In the functional analysis, the system requirements are translated into detail design criteria, and specific requirements at subsystem levels are identified. The proposed solution to the problem is provided in terms of flow diagrams displaying the logical sequence of all functions during operation. In addition, the functional analysis includes the operational and support activities for the entire system. Figure xxx to yyy are the included diagrams in this functional analysis. They describe the: System level diagram Mission level diagram System level functional diagram First level functional diagram
5.1.
System Level Diagram

Large cut-off valve
Isolate turbine Emergency / maintenance
Long lifespan Non-corrosive Withstand varying loads
Maintainability
Convenient Installed in penstock / large conduits Flanged connection
Valve operation
Easy assembly
Manual valve operation Hand-wheel/lever gear shaft assembly
Automated valve operation Electric/hydraulic/ pneumatic actuator
Accessible lubrication locations
Figure 12: System level diagram
Ergonomic
Closure time < 60 sec 26 | P a g e Design of a large cut-off valve
MOX_410 [JUNE 2012]
5.2.
Mission Level Diagram
Mission level design parameters: Isolate turbine Flanged connection Compatible with hydropower equipment Acceptable life expectancy Dia. = Penstock diameter Closure time 60 sec max. Maintainable Reliable Simplicity Safe Easy dis./assembly Resistance to environment hazards Use existing proven equipment Manual and automated operation
Support hydropower activity 0.0
Isolate hydropower turbine 1.0 Scope of the project
Cut-off valve is functional 2.0
Figure 13: Mission level diagram
MOX_410 [JUNE 2012]
5.3.
System level function diagram
Position valve upstream from turbine 1.1
Connect valve to penstock by flanged coupling 1.2
Valve is functional 2.0
Isolate hydropower turbine 1.0
Attach valve actuator 1.3
Fully open valve 1.4
Fully close valve 1.5
Scope of project
Figure 14: System level functional diagram
MOX_410 [JUNE 2012]
5.4.
First level functional diagram
Position valve upstream from turbine 1.1
Place in position 1.1.2 Carry to penstock 1.1.1 Turn till bolt holes are aligned 1.1.3
Ensure there is enough space for valve actuator 1.1.4
Connect valve to penstock by flanged coupling 1.2
Apply sealant on flanged surfaces 1.2.1
Insert gasket if required 1.2.2
Insert bolts & nuts 1.2.3
Tighten bolts & nuts 1.2.4 No Is valve secure?
Test manual operation 1.3.3 Attach valve actuator 1.3 Assemble actuator mechanism 1.3.1 Attach actuator to valve body 1.3.2 No Is assembly secure? Test automated operation 1.3.4
MO: turn hand wheel to fully open 1.4.1 Fully open valve 1.4 AO: press fully open button 1.4.2 No Is valve fully open?
Figure 15: First level functional diagram
Fully close valve 1.5
MOX_410 [JUNE 2012]
6. Design Requirements
The cut-off valve design project should meet the specified client needs, which are converted to design requirements in order to be measurable. Any additional specifications unmentioned by the client will be provided during the design phase according to the relevant environmental factors, ergonomic and design standards. The importance of each of the requirement ranges from 1-5; 1 being the most important and 5 being a flexible requirement which could be changed along the design phase.
Table 8: design requirements
1 2 3 4 5 6 7 7.1 7.2 7.3 7.4 8 9 10 11 12 13 14 15
Design Requirement Used in hydropower plant Water flow speed Valve diameter Closing duration Valve & piping attachment Tight seal Dynamic & Static loading limits Transverse load Axial load Bending Moment Torsion Reliable Ease of operation Economical Wear & corrosion protection Long life span Manufacturability Ease of assembly Maintainability
Importance 1 1 2 1 1 5 1
Metric m/s m s N or N.m
Specification 10MW output, 30 m head 9 <60 Seconds Flanged couplings -
<10 kN <100 kN <1 kN.m <1 kN.m 3 3 3 1 3 2 3 2 R hours All parts Manual/automated Acceptable life Simple components Replaceable parts
MOX_410 [JUNE 2012]
7. Concept generation
Different concepts were generated for each of the subsystems as determined in the functional analysis. These subsystems are: main valve type, torque unit, supporting valve legs and associated valve functional part (disc, plate, cone, or ball) which depends on the valve type chosen.
Table 9: Concept generation for the main valve Concept Short Description Butterfly valve This concept uses a disc that rotates ninety degrees to open and close the valve Spherical valve This concept uses a rotor shaped like a ball and has a full bore through it. The ball rotates ninety degrees to stop or start flow. Cone valve This concept uses a conical plug that contains a full bore. The plug is lifted, rotated ninety degrees, and lowered to control flow. Gate valve This concept uses a plate that moves linearly into and out of the waterway.
Picture
Good aspects
Compact Quick rotation operation Simple components Disc introduce flow restriction High torque requirements
Quick rotation operation Complex components Minimal flow restriction Bulky Large No of components Difficult to manufacture the ball High torque requirements Low maintenance cost High capacity Long term service Good flow control
Slow linear-rotation operation Complex components Minimal flow restriction Bulky Difficult to manufacture the cone Complex working operation High torque requirements Low maintenance cost High capacity Long term service High pressure operation
Quick linear operation Simple components Little flow resistance Requires a slot for plate that make valve wide Complex torque unit Low overall cost High capacity Poor flow control
Bad aspects
Specific parameters
Low overall cost High capacity Easy maintenance Long term dependable service Good flow control
MOX_410 [JUNE 2012]

Table 10: Concept generation for torque unit
Concept Short Description
Hand wheel actuator This concept offers manual operation in which valve is closed or opened by rotating the wheel, although it may require gear assembly.
Electric motor actuation This concept uses a motor to drive a gear assembly to open and close.
Hydraulic cylinder actuator This concept uses a double piston which opens and closes valve when pressure is introduced. The pressure can be provided by air, water, or oil.
Picture
Good aspects
Manual operation, no power source is required Can be made by the user
Automated precise operation Adjustable for best closure time
Bad aspects
Specific parameters
Valve closure is dependent on the operator/personnel Requires gear assemble Reliable Almost maintenance free Low cost
Requires power source Bulky, although smaller versions can be found Efficient High maintenance High cost
Smooth automated operation Adjustable for best closure time No electric power source required Could be used with a closing weight Acts as hydraulic damper during closure Bulky
Efficient Low maintenance Relatively high cost
MOX_410 [JUNE 2012]

Table 11: Concept generation for support structure
Concept Short Description
Two point support This is a concept of two support columns welded onto sides of valve body. The columns have plates at the bottom to be bolted on the ground support.
saddle support This is a concept of a thick plate with webs welded around the bottom arc of valve body.
One point support This is a concept of one wide column attached by welds at middle with one large bottom plate for bolting onto ground.
Picture
Good aspects
Less material Easily replaceable legs when damaged Less weld area Damage to one leg could result in valve rolling over to the side Low reliability Low cost Shaky Difficult assembly
large weld attachment area firm support webs offers more strength Difficult to manufacture
less material simple support relatively large weldment area Large cross-sectional area
Bad aspects
Specific parameters
High Reliability High cost Sturdy Easy assembly
Low reliability Low cost Easy assembly
MOX_410 [JUNE 2012]
7.1.
Concept evaluation and selection
7.1.1. Concept rating and selection The following concept scoring matrix in table 4 is used. The weight column gives the relative importance of the selection criteria. The scoring is determined by the weighted sum of the rating. Ulrich and Eppinger (2008:135) recommend the scale from 1 to 5 with the simplest concept chosen as reference concept for comparative ratings.
Table 12: Concept rating Relative performance Much worse Worse Good Better Much better Rating 1 2 3 4 5
The valve type concepts evaluation is as follows:

Table 13: Valve type concept evaluation matrix Selection Criteria Flow restriction Flow control Maintainable (no. of parts) Manufacturing ease (complexity of parts) Quick operation Cost of manufacturing Ease/quick assembly Compact Light reliability Weight 0.15 0.15 0.10 0.10 0.05 0.20 0.05 0.05 0.05 0.10 Total score Continue? Gate valve Rating Weighted Score 5 0.75 2 0.30 3 0.30 4 0.40 5 0.25 3 0.60 2 0.10 3 0.15 3 0.15 3 0.30 3.3 no Butterfly valve Rating Weighted Score 4 0.60 4 0.60 5 0.50 4 0.40 5 0.25 4 0.80 3 0.15 4 0.20 3 0.15 4 0.40 4.05 yes Spherical valve Rating Weighted Score 5 0.75 3 0.45 2 0.20 3 0.30 5 0.25 2 0.40 1 0.05 2 0.10 2 0.10 5 0.50 3.1 no Cone valve Rating Weighted Score 5 0.75 3 0.45 4 0.40 3 0.30 3 0.15 2 0.40 2 0.10 3 0.15 1 0.05 5 0.50 3.25 no
MOX_410 [JUNE 2012] The torque unit concepts evaluation is as follows:

Table 14: Torque unit concept evaluation matrix
Hand wheel Selection Criteria Power source requirement Adjustable for best closure time Maintainable Cost reliability Efficient Simplicity Compact Quick operation Durability Weight 0.15 0.15 0.10 0.10 0.05 0.20 0.05 0.05 0.05 0.10 Total score Continue? Rating 5 2 3 4 5 3 3 3 3 3 Weighted Score 0.75 0.30 0.30 0.40 0.25 0.60 0.15 0.15 0.15 0.30 3.35 no
Electric motor Rating 4 4 5 2 5 4 1 4 3 4 Weighted Score 0.60 0.60 0.50 0.20 0.25 0.80 0.05 0.20 0.15 0.40 3.75 yes
Hydraulic cylinder Rating 5 3 2 3 5 2 1 2 2 5 Weighted Score 0.75 0.45 0.20 0.30 0.25 0.40 0.05 0.10 0.10 0.50 3.1 no
MOX_410 [JUNE 2012] The support structure concepts evaluation is as follows:

Table 15: Support structure concept evaluation matrix
Two point support Selection Criteria Less material Firm structure Maintainable Cost reliability Efficient Simplicity Compact Weld area Durability Weight 0.15 0.15 0.10 0.10 0.05 0.20 0.05 0.05 0.05 0.10 Total score Continue? Rating 5 2 3 4 5 3 2 3 3 3 Weighted Score 0.75 0.30 0.30 0.40 0.25 0.60 0.10 0.15 0.15 0.30 3.3 no
Saddle support Rating 4 4 5 3 5 4 3 4 3 4 Weighted Score 0.60 0.45 0.50 0.30 0.25 0.80 0.15 0.20 0.15 0.40 3.8 yes
One point support Rating 5 3 2 4 5 2 4 4 2 3 Weighted Score 0.75 0.30 0.20 0.40 0.25 0.40 0.20 0.20 0.10 0.30 3.1 no
MOX_410 [JUNE 2012] 7.1.2. Concepts Modification In this subsection, the concepts selected are refined for best possible use of material and ultimately the design. Any good features from the left out concepts which can be integrate in the selected concepts, is investigated further. Main body concept The main body concept to be used for the purpose of this design is that of a basic butterfly valve with flanged end connections. No changes are necessary for this concept because the shape of the body is very simple and similar in all butterfly valve designs.
Figure 16: final model of the main valve body
Torque unit concept The torque unit is required for the closure and opening operations of the valve. The torque unit should not cause damage to the disc seat when opening the valve as this is normally the case. An electric motor actuator is selected and will be used as the primary mechanism for the valve operation. In cases of power failure, the valve still needs to be operable, and therefore, a handwheel will be included as a secondary mechanism. The torque unit that slows down when near closing will be design and the actuator can be mounted on it.
Figure 17: final model of the torque unit
MOX_410 [JUNE 2012] Support structure concept Large valve designs require a supporting structure to carry the weight of the valve instead of it being carried by the piping system. The saddle support will be used. Modification of the support is required to reduce the final weight of the valve. The saddle will be built from three leg supports when looking from the side and small plates will be welded in between the legs for strengthening.
Figure 18: final model of the support structure
Final product
Figure 19: Final assembly of the product
MOX_410 [JUNE 2012]
8. Detail Design
8.1. Penstock pressure
The penstock and the cut off valve should be capable of withstanding full pressure due to static head caused by maximum elevation of the operation range for the intake pool. The pressure at any point in the penstock can be easily calculated if the head at that point is known.
Figure 20: Maximum head of hydropower plant
(Equation 1)
Specific weight of water: = 9790 / Maximum head: = 30 = = 9790 30 = 294000
The pressure rating of the penstock should be 2.94 bars. If the penstock used has a pressure rating less than the calculated value, then there would be risk of a pipe burst. The wall of the valve to be designed should be thick enough to withstand this operating pressure as well.
MOX_410 [JUNE 2012]
8.2.
Valve Housing
8.2.1. Valve Flow Rate The first part of the design is to determine the water flow rate required to run the 10MW turbine. The power output of a hydropower facility depends on the net head available to the turbine and is given by the equation: =
Table 16: Given Information of hydropower plant
(Equation 2)
Property
Value 30
10 10 998 / 9.81 /
@ 1 20
The overall efficiency of the plant tends to vary between 40 and 80 percent and is expressed as follows: = = 0.69 = = 0.85 0.95 0.95 0.9
(Equation 3)
The approximate water flow rate
= 10 10 0.69 998 9.81 30 = 49.34 / The calculated flow rate gives an approximated discharge of the turbine at optimal operating condition. Therefore, the penstock or conduit should be large enough to supply this flow rate. 8.2.2. Internal Valve Diameter The internal diameter of valve should be equal to the diameter of penstock. The diameter of both the valve and penstock is important because it affects the power available to the turbine. The optimum diameter is given by the following formulae: =
.. .
(Equation 4)
MOX_410 [JUNE 2012] = 0.52 10000 =

.
. .
. = 3.55 30
(Equation 5)
= 1.12 49.43
. = 4.30 30
The values calculated above are correct within 10 and 20 percent respectively. The formulae used are based on construction cost, maintenance cost as well as the piping head losses and the diameter estimates obtained are quite large. Fluid flow through a pipe is also given by: = = /4 = 4
Maximum fluid velocity is given to be 9 / , therefore
= 4 49.34 9 = 2.64
The rounded off internal diameter of the valve is chosen to be with width of . With the flow rate kept constant at 49.34 / and the selected valve diameter, the anticipated maximum water velocity is: = 8.62 / < . 9 = = 49.34 0.25 2.7 8.2.3. Valve shell thickness
The valve can be thought of as a short tube with closed ends. Any tube carrying fluids at high pressure develop both hoop and longitudinal stresses. The valve body is usually built from gray cast iron or ductile iron. The method followed for wall thickness is adopted from Shigley p.108 and the following assumptions apply. The walls are subjected to plane stress No discontinuities in the walls are considered The wall thickness is less than = 67.5, hence thin-walled vessel theory apply
MOX_410 [JUNE 2012]
Figure 21: Pressurised valve shell
Material selected for the valve body is ductile iron 60-40-18 with properties, = 414 and = 276 Case 1: static loading Longitudinal stress = 4 = 2 = 0
(Equation 6)
= 294000 2.74 = 198500/ Hoop stress

(Equation 7)
= 294000 2.72 = 396900/ And shear stress The ordered principal stresses are: = 396900/ , = 198500/ , = 0 Distortion energy theory (Von Mises stress) = 1 [ + + ] 2 = 344000/ =

(Equation 8)
= 1 [396900/ 198500/ + 198500/ 0 + 0 396900/ ] 2
Pressure vessels use safety factor of 3.5 to 4. The safety factor of 4 will be used.
0.005
= 344000 = 276 10 4
MOX_410 [JUNE 2012] Case 2: dynamic loading The pressure is cyclically applied onto the contents of the tube between maximum pressure during operation and zero pressure when not operated. The stresses are assumed to fluctuate between the following extremes: , = 4 , = 0
, = 2
, = , = 0
, = 0
Amplitude and midrange components , = 99250/ , = , = 0 , = 99250/
, = 198450/ , = 198450/
Principle stresses , = 198450/ , = 198450/ , = 99250/ , = 0 , = 99250/ , = 0
Using Von Mises alternating stress approach

= 1 [198450/ 99250/ + 99250/ 0 + 0 198450/ ] 2 = 171862/ =
Using Goodman criteria

+ =
(Equation 9)
/ .
From figure 35, cast iron, ASM International handbook committee p.75, the endurance limit for ductile iron 60-40-18 is 205 for unnotched specimen. = = 0.005 +
/
The nominal wall thickness of ductile iron penstock is a function of the nominal size (NB) using the formula given WINSEN DCI Piping systems. = 0.5 + 0.001
(Equation 10)
MOX_410 [JUNE 2012] Where NB equals the internal diameter of penstock and K is a class thickness coefficient ranging from 7 to 14. = 70.5 + 0.001 2700 = 22.4 7 From the catalogue provided by WINSON DCI Piping system, a class 8 (K=8), the thickness of a pipe of nominal size of >1200 mm is taken as 13.5 mm. The recommended minimum shell thickness for steel penstocks to provide the rigidity required during construction and handling is given by (Gedeon, 1995): = + 400 2700 + 500 400 = 8
(Equation 11)
Where D is the diameter of the penstock in millimetres and K is 500 =
Shell thickness of will be used to compensate for grooves for disc seats, corrosion wear, stiffness requirement, and handling requirements. 8.2.4. Valve End Connection There are three common methods for installing valves in pipelines; welded end connection, bolted gasketed flanges, and screwed pipe threads. The client requested that the end connections be of flanged type for ease of valve removal from piping. The common flanged end connections include flat face, raised face, and ring type joint as shown below.
Figure 22: Most common flanged end connection for valve
The raised face flange end connection has a circular raised face with inside diameter the same as the valve opening. The raised face is finished with concentric circular grooves for good sealing and resistance to gasket blowout. This type of flange is used with a wide variety of gasket materials and flange materials for pressures through the 414 bar pressure range and for temperatures up to 800 degree Celsius. The raised face flange type is normally standard on cast iron bodies. The flanges to be used on the valve being design are CLASS 175 raised face with welding neck. The flange specifications were extrapolated from the forged steel flanges catalogue as the largest nominal diameter data was less than that of 2700mm.
MOX_410 [JUNE 2012]
Figure 23: forged steel flanges specifications
Table 17: Extrapolation method Nominal size. Flange O.D x 2134 2388 2693 ?
y 2438 z 2700
= = 2700 2438 + 2693 = 2956

Table 18: Calculated flange specifications in millimetres and kilograms
Flange outside dia. 0 2956
Flange Length thickness thru C hub Y 99.8 201.2
Dia. of Dia. of No of Hole hub at raised holes dia. base X face R 2802.7 2856.7 102 35
bolt dia.
Bolt circle dia. K 2891.6
Approx. weight
31.75
1053.6
8.2.4.1.
Bolt Connections
Bolt connection to penstock The maximum bolt loading will occur upstream of the valve when in a closed position. The separating force is expressed in terms of the pressure acting on the disc face, thus pushing the valve away from the penstock. All the bolt calculations follow method provided in Shigley Chapter 8. 45 | P a g e Design of a large cut-off valve
MOX_410 [JUNE 2012] = = 294000 5.726 = 1683.44
Figure 24: valve - penstock bolt connection
Bolt and Nut selected: Grade 4.6 M30 Hex head bolt (table A-27), and M30 Regular Hex Nut (table A-29) = = 99.8 = 199.6 = 25.6 Adding two threads beyond nut of 7 mm in gives a bolt length of: = 199.6 + 25.6 + 7 = 232.2 The next fraction bolt size is = 250 (table A-15)
= 2 + 25 > 200, = 85
Eq 8-14 Table 8-7 Table 8-7
= 199.6 165 = 34.6 = From table 8-1, = 561 = 0.25 30 = 701 = 207

= 250 85 = 165
Eq 8-17
= . = 696.86 /
.
.. ..
Eq 8-21
= 100 =
.
... ...
= 2211.15 / = .. = 0.2396 46 | P a g e Design of a large cut-off valve

.
MOX_410 [JUNE 2012] Portion of separation force taken by bolts = = 0.2396 1683.44 = 403.4 Portion of separation force taken by members = 1 = 1 0.2396 1683.44 = 1280
From table 8-9, bolt proof strength = 225 = 0.75 = 0.75 561 225 = 94670
The recommended preload for non-permanent connection and reusable fasteners is:
Eq 8-30
The number of bolts required to hold the connection together with a load factor guarding against joint separation of = 4 is:

..
= 51.13
Eq 8-28
Therefore, 52 bolts will be satisfactory. To maintain adequate uniformity of gasket pressure, adjacent bolts should be placed no more than six bolt nominal diameters apart on the bolt circle. With 52 bolts, bolt distance is
.
= 55.6 < 6 35 = 210
A rough rule for bolt spacing around a bolt circle 3 2891.6 6 3 52 35 6 3 4.99 6
Therefore, the recommended flange bolt number of 102 wont be used. 52 bolts with bolt spacing of 55.6 mm are recommended. The torque necessary to develop the preload: =
Eq 8-27
From table 8-15, = 0.20 for zinc-plated bolt condition = 0.20 30 10 94670 = 568 .
52 bolts will be used instead of the number of bolts given in table-18. The required torque to develop bolt preload is 568 . . End-connection gasket A full gasket will be inserted for sealing of the connection between the valve and the penstock. The gasket area is: = 0.25 R is the diameter of the raised face and ND is the nominal size of the flange. = 0.252802.7 2700 = 0.444 47 | P a g e Design of a large cut-off valve
MOX_410 [JUNE 2012] = = <0

= 2 1280 10 94670 . = 139 .
8.3.
Minimum Disc Thickness
The disc will be fixed by the valve shaft in the middle and bottom half of the disc will also be supported by a shoulder for the seat as depicted in the figures below. The maximum loading on the disc will occur in the vertically closed position. The assumed opening rotation is anti-clockwise.
Figure 25: Disc held in position by shaft and seat shoulder
simply supported periphery as adopted from mechanics of engineering materials (Benham et al, 1996).
The disc strength will be estimated by a plate of radius 2 subjected to uniform pressure and with
Figure 26: Symmetrical bending caused by the uniform loading The disc shall be constructed from 65-45-12 ductile iron with properties; = 448 , = 310 , and = 0.26 Maximum stress will occur at the center of disc and is given by: = 3 3 + 32
(Equation 12)
Using a safety factor of 1.2, the required disc thickness is computed as follows:
MOX_410 [JUNE 2012] =

3 +
= 0.0504
.. 3
+ 0.26
The minimum valve disc thickness shall be taken as The deflection shape estimate used above does not represent what will happen to the disc in reality. The actual shape of valve disc will take the shape depicted in the diagram below.
Figure 27: actual deflection of the valve disc
To calculate the maximum deflection in the disc using the theories learned in the previous design modules would be tedious task. As recommended by the client, simulation studies were performed (see appendix C, simulation of valve disc) to predict what the maximum deflection will be. The material properties and results of the simulation are tabulated below:
Table 19: valve disc simulation results
Properties Disc Material Malleable cast iron Yield strength Ultimate tensile strength Poissons ratio Density Support bars material AISI 4340 steel, normalized Yield strength Ultimate tensile strength Poissons ratio Density
Value & units = 276 = 414 = 0.27 = 7300 / = 710 = 1110 = 0.32 = 7850 /
Results for plane disc Max stress 218 Max strain 7.644 4 Max displacement 17.35 Mass 3370 Results for disc with bars Max stress 164 Max strain 6.883 4 Max displacement 3. 706 Mass 4004.5 The disc having support bars on the top half circle has significantly smaller maximum displacement compared to plane disc. 49 | P a g e Design of a large cut-off valve
MOX_410 [JUNE 2012]
8.4.
Load Analysis of Shaft
The assembly of the shaft and disc in the valve housing is represented by the diagram in figure-25.
Figure 28: Typical assembly of the valve shaft and disc
The following loads are based on the valve installed in a horizontal pipe, with the valve shaft also positioned horizontally in the valve. The maximum loads will occur with one side empty as shown in the figure below. The water forces above and below the disc appears to be unbalanced and tends to open the valve.
Figure 29: Pressure loading on the disc
Disc mass: 4004.5
= = 4004.5 9.81 = 39284.145 =

The weight of the disc acting on the shaft is assumed to be distributed along the shaft. =
. .
= 14.6 /
MOX_410 [JUNE 2012] Pressure loading on the disc = 2 = 30
= + = 306916.5 =
2.7 9790 = 280484 2
The distributed loading on the shaft per unit length is:
Disc area: = 4 = 2.7 4 = 5.726

Offset pressure: = = 26432.5 The offset pressure can be replaced by a resultant force per meter and moment arm (torque) on the shaft as follows: = = 26432.5 5.726 = 28.03 /
.
= 280484 5.7262.7 = 595 /
= = 28.03 2.7 0.9 = 34.06 . 8.4.1. Shear Force and Bending Moment
This force act at: = = 2.7 = 0.9 from the bottom of the valve
Figure 30: Reaction forces on the shaft
Reaction forces in the y-z plane = = = 14.6 2.7 = 19.71

= = + = 2.7 623 = 841.05
MOX_410 [JUNE 2012] Shear force and bending moment diagrams
Figure 31: Shear force diagrams in y-z and x-z planes
Figure 32: Bending moment diagrams in both y-z and x-z planes
Shear forces at point 1 and 2

= +
= 19.7 + 841.05 = 841.3
Bending moment at midpoint

+ =
= 13.3 + 567.7 = 568 . Torque = 34.06 .
MOX_410 [JUNE 2012] 8.4.2. Shaft Strength and Life Expectancy Shaft material shall be 1095 steel (quenched & tempered) with yield strength of 813 and ultimate strength of 1260 . Using distortion energy theory and safety factor of 1.5 at maximum bending moment (midpoint), the minimum diameter requirement is computed from the expression as given in Shigley, chapter 6:
= 16 4 + 3
The unknown torque is initially taken as zero =

. 4
= 277.53 = 8.4.2.1.
568 10 + 3 34.06 10
Shaft fatigue strength

Eq 6-19
Surface factor (machined finish): = 4.511030. = 0.72 Size factor (51<d<254, but d> 254), shaft is treated as non-rotating = 0.37280 = 103.6
Eq 6-24 Eq 6-20 Eq 6-26 Eq 6-28 Eq 6-29
= 1.51103.6. = 0.73 Loading factor (bending): = 1 Temperature factor (T around 20): 1 Miscellaneous factor: = 1 Modified endurance limit
= = 0.5
Reliability factor (90% reliability): = 0.897
Eq 6-18 & 6-8
= 297
= 0.720.73110.89710.5 1030
Notch sensitivity and Stress concentration The shaft is straight along its length, therefore there will be no notch sensitivity. Hence, no stress concentration factor exit on the shaft. The amplitude stress components The alternating bending stress is: = 53 | P a g e Design of a large cut-off valve
MOX_410 [JUNE 2012] = 1 at midpoint of the shaft, since there is no stress concentration factor For bending; = 64 =
= 1 568 10 0.14 = 263.3 30.2 10 .
= 30.2 10 , =
= 0.14
For torsion; = 32 =
The alternating torsional stress is: = 2

.
= 1 34.06 10 0.28 = 7.9 2 60.34 10
= 60.34 10
The midrange stress components = =

. ..
+ 3 The von Mises components are computed from = = 263.3 + 3 10.7 = 264 = 3 13.7 = 23.73
= 0
= 13.7
The fatigue factor of safety, computed using modified Goodman 1 1 = = 264 23.73 = 1.1 [OK] + 297 + 1260 8.4.2.2. Shaft life expectancy
Shaft failure will probably occur at midpoint, which is a point of maximum moment or at either point 1 or 2, which are points of maximum shear force. The midpoint of the shaft has no stress concentration. At midpoint, the reverse bending stress is, assuming infinite life, =
This stress is less than both and . This means that shaft life is infinite and there will be no yielding on the first cycle.
= 64 =
= 265
= 30 10 , = = 0.14
MOX_410 [JUNE 2012] For ultimate strength of 1260 , fatigue strength fraction = 0.78 from figure 6-18 shigley.
0.78 1260 297 = 3252

= log
= log0.78 1260297 = 0.1732 =
= 2133252
= 6.810 ][
8.5.
Bearing Selection
Bearings are required to permit smooth low friction rotation of the disc when opening and closing. Vesconite Hilube bushes were selected for mounting the disc onto the bearing housing of the valve body. The selection of the Vesconite Hilube bushes was based on factors such as long life, wet operation, low maintenance and low friction. These types of bushes are known to perform well under high loads with low speed. The bush size, clearances and tolerances are calculated following the Vesconite and Vesconite Hilube Design Manual. 8.5.1. Application Assessment 1) Loading = =

+ = 4004.5 + 1681 = 2843 2 2
= 9.81, = 150 and = 280 = 0.664 =

The transferred pressure from disc onto each bush is: =

.
= 28 + 0.664 28 55 | P a g e Design of a large cut-off valve
= 28
MOX_410 [JUNE 2012] 2) Sliding speed for rotation The valve is expected to close with one minute, thus making a quarter revolutions = 0.25 / =
= 0.22 /
3) PV limit for load and speed combination = 28 0.22 = 6.16 . / The level of lubrication is determined by the PV limit. For PV of less than 8 for Vesconite Hilube, no lubrication is necessary although initial greasing would greatly increase wear life (From the table provided in the manual, see APPENDIX). Vesconite can also be lubricated using clear water and sea water.
Table 20: Summary of bush dimensions, clearances and tolerances
Bearing Material Shaft diameter (d) Bearing length L Wall thickness (Moderate PV value) = 0.05 Housing diameter (HD) = + 2 Press fit (PF) = 0.05 + 0.002 Bore closure (BC) = / Assembly clearance (AC) = 0.05 + 0.02 Bush dimensions = + = + + Temperature compensation 0 < < 70
VESCONITE HILUBE WITH INITIAL LUBRICATION 280 150 14 308 0.666 0.7326 0.33
308.67 281.06 -
8.6.
Seals Selection
The valve will require sealing off the shaft as well as the flanged end connections. The shaft seal is usually a packing box with packing retained and adjusted by a flange and bolts. The end connection seal are gaskets clamped together by bolt connection. 8.6.1. Shaft seals The primary sealing of the shaft is provided by the interference fit between the rounded polished disc hub and bearing housing hub. The two hubs are made of stainless steel and integrally moulded onto the parent bodies respectively. The hubs would require high precision machining for the inside diameter and width to maintain drop-tight seal.
MOX_410 [JUNE 2012] A single PTFE V-Ring packing that uses a coil spring between the packing and follower shall be used as secondary sealing for the shaft. The packing maximum pressure is rated at 20 bars and can operate between temperature -18C and +93C. The arrangement of the packing is as follows.
Figure 33: single PTFE V-Ring packing for sealing the shaft
8.6.2. Disc Seat The seal on the disc incorporate an off-set disc with shaft located beyond the plane of the plane of the valve seat. The seat is made out of a rubber (BUNA-Nitrite) held in place by screw-on retaining ring (Seal cover), together with Seal holder that is welded onto the inside of the valve housing (cylindrical ring) as shown in figure-31.
Figure 34: Arrangement of the disc seal
The mating of the disc with the rubber seat is accomplished by compressing the rubber such that the rubber displacement is greater than the actual disc deflection. The installation is built for ready removal, adjusting, or replacement of the rubber in case of excessive wear or other damages. The rubber material is chosen for its high abrasive resistance to solid materials in the dam water as well as resistance to chemical degradation than most metal seats. It is recommended that the rubber be treated with peroxide to yield better characteristics of the elastomeric material. 57 | P a g e Design of a large cut-off valve
MOX_410 [JUNE 2012]
8.7.
Valve torque and Actuator Sizing
The torque is computed to allow proper actuator selection and to provide assurance that the valve components can withstand the internal forces produced by the water flow as well as the pressure. Butterfly valve torque consists of various elements that contribute to the total valve operating torque. The torque and flow coefficients estimates are based on the installation of valve in straight horizontal pipe without flow disturbances on either upstream or downstream. The maximum differential pressure is required for the calculation of valve torque. The downstream pressure is not known and will be approximated by the outlet pressure of the turbine in an open position. The turbine discharges water into a tale race canal at atmospheric pressure. When closed, the pressure difference is highest and the internal pressure is equal to atmospheric pressure at empty downstream side. = = 2.94 1 = 1.94 8.7.1. Valve torque analysis 8.7.1.1. Bearing torque
The bearing torque is a function of valve shaft diameter, the static coefficient of friction between the bearing and shaft, disc diameter, and the pressure drop across the disc. Bearing torque is always positive as it opposes disc rotation.
=
The dynamic and static unlubricated friction of Vesconite Hilube against steel goes as low as 0.08 [19]. = 0.08 1.94 10 2.7 .28 = 99.5 . The bearing torque is highest at closed or near-closed position because the pressure difference is maximal when the valve is closed. This torque is reduced drastically as the valve reaches the fully open position.
Figure 35: Bearing torque on the shaft
MOX_410 [JUNE 2012] 8.7.1.2. Centre of gravity torque
This torque is caused by the offset introduced in the disc which offset the centre of gravity of the disc. The gravity torque is a function of disc position and the weight of disc. The value of gravity torque is maximal when the valve is closed. This torque is negative because it turns to open the valve. = sin
Centre of gravity: = 0, = 9, = = 103 Arm of rotation: sin = = 103 Mass: 6500
= 9.81 6500 0.103 = 6.6 .
Figure 36: centre of gravity torque
8.7.1.3.
Hydrostatic torque
Hydrostatic torque is a maximum when one side of the pipe is empty (closed position) and zero when valve is open. This torque was calculated in shaft loading analysis. = 34 . 8.7.1.4. Seating torque
The seating torque is due to the friction and interference between the valves rubber seat and the mating surface. It usually refers to the required to rotate the valve disc into, and out of, the rubber seat. For the current design, the disc pushes against the seat, and therefore, the seating torque can be assumed to be zero. The total effect can only determined by tests. = 0
MOX_410 [JUNE 2012] 8.7.1.5. Packing and hub torque
The packing caused friction between the shaft and the bearing housing and the hub seals cause similar effects. This toque is always positive as it opposes rotation of the disc. The shaft seal used is a V-packing type and causes insignificant torque which can be ignored. = 0 8.7.1.6. Dynamic torque
Dynamic torque is a torque induced by water flow and is a function of valve geometry, flow rate, and valve position. In butterfly valves, the maximum coefficient of dynamic torque occurs at around 65 to 80 degree open position. The maximum torque on the valve, i.e. the summation of all operating torque requirement, normally occurs at intermediate positions ranging from 0 to 50 degree, where the pressure difference is high. The dynamic torque is dependent on the piping system and cannot be assumed without system analysis at this point. Thus, this value will be neglected for the calculations of the total operating torque. = 0 8.7.2. Torque components The maximum operating torque is the turning force needed to rotate the disc and is given by the following summations of different torque components. The highest of the torque components will be used for actuator sizing. Breaking torque: = + + + + = 99.5 + 6.6. +34 + 0 + 0 = 140.1 . Opening torque: = + + + = 99.5 + 6.6. +0 + 0 = 106.1 . Closing torque: = + + = 99.5 + 6.6. +0 + 0 = 106.1 . 8.7.3. Torque Unit The torque unit was considered to provide characterised closure and opening of the valve in which the valve slowly close during the last portion of disc travel to assist in reducing pipeline surge. The torque unit uses a travelling crosshead to impart positive rotation to the disc by means of a rotary link connected to the shaft. The crosshead travels in a straight line through the power screw and the supporting rods.
MOX_410 [JUNE 2012]
Figure 37: Torque unit
Torque requirement of the power screw For a safety factor = 1.2 to account for valve torque variation, the maximum operating torque is given by the breaking torque: , = = 140.1 1.2 = 168.12 . The crosshead force onto power screw
Figure 38: forces on the screw and the caller caused by torque
, .
Select a single thread square power screw with nominal diameter = 56 and pitch = 5.5. all the calculations are based on Shigley, chapter 8. The thread depth and thread with are equal, = = 56
.
. .
= 560.4
Minor diameter, = = 50.5 Mean collar diameter, = Lead, = = 1 5.5 = 5.5

= 53.25
= 53
MOX_410 [JUNE 2012] Coefficient of friction for threaded pairs is = 0.06 for crosshead and screw material of Bronze (table 8-5). Thrust collar coefficient of friction is = 0.08 for hard steel on bronze and starting (table 8-6). The torque require to turn the screw against the load (opening or breaking of the valve) = =
+
.. ... .. + ...
= 2580 .
Overall efficiency in turning the shaft = =

The body shear stress due to torsional moment at the outside of the screw body

..
= 0.19
= 102
The axial nominal normal stress = =
. .
= 280 = 462.9
Bearing stress with one thread carrying 0.38F = =

.
= =
.. ..
Thread-root bending stress with one thread carrying 0.38F

. .. ..
= 961.2
Three dimensional stresses = 961.2 = 0
= 0 = 102 = 462.9 = 0
961.2
Von Mises stress = + 462.9 + 462.9 + 961.2 + 6 102 = 1270 56

.
Maximum shear stress , =

+ + 102 = 559, 96 62 | P a g e Design of a large cut-off valve
, =
MOX_410 [JUNE 2012] =

= 559 96 = 231
The material used for both the crosshead and power screw is bronze and should be treated to achieve yield strength of more than 1270 56 to ensure that the power screw does not fail under the valve torque loading. 8.7.4. Actuator sizing The valve will use two actuators; electric motor for automated operation and a hand-wheel for manual operation in case of power failure (redundancy). The shaft is required to make a quarter turn for full closure or opening. The power screw as designed above moves at 5.5 per revolution and the crosshead should cover 600 in no more than one minute. Require screw angular speed =
.
= 109.1 /
Electric motor actuator The gearbox of the electric motor actuator is normally sized based on the break and the running torques provided. It is recommended that the motor-gearbox be sized with a safety factor = 1.5. Require power output of the motor =
= 1.5 2580 109.1 = 44.2 TMW Torque Motors, 400 VAC Power supply. Product number TMW306LS shall be used. Technical data of the motor are: Range speed: Power output: Maximum torque: 100-125 rpm 53 kW 4810 N.m
Figure 39: TMW torque motor
MOX_410 [JUNE 2012] TMW torque motors selection was based on the following characteristics. High torque at low speed No gearbox High torque density Silent operation Customized mechanical Interface Other advantages of the TMW torque motor is that they come in simplified installation. The shaft end options includes hallow shaft with key or double key for simple coupling (see Appendix D).
MOX_410 [JUNE 2012]
9. Design Analysis
Every design process is analysed with regards to manufacturing, maintenance, reliability as well as cost.
9.1.
Manufacturing Analysis
The large cut-off valve would require a variety of manufacturing processes, as this type of valves are usually assemblies of a considerable amount of components. The valve parts are to be manufactured with tolerances set to provide interchangeability of parts between units of the same size and type. The manufacturing process of the valve would probably be carried out as a sequence of operations. In this subsection, the manufacturing schedule for two valve components is described as well as the manufacturing processes involved for all non-standard parts. 9.1.1. Valve shaft manufacturing process The large diameter of the shaft is 280 mm, and the small diameter is 140 mm. Its length is 3800 mm. The material selection of the shaft was based on the high strength of 1095 steel that is quenched and tempered. The material can be purchased at different diameters and lengths, and since the dimensions of the purchased material are not necessarily ideal, material removal processes will be required for shaping operations in which excess material is removed from a starting work-part so that the desired final geometry is obtained.
Figure 40: Valve shaft with differing diameters and connection holes
MOX_410 [JUNE 2012] A typical shaft manufacturing process would follow a path similar to the one depicted in the diagram below: Turning & related operations
Conventional machining
Drilling & related operations
Material removal processes
Abrasive processes
Milling
Unconventional machining
Other machining operations
Figure 41: typical shaft manufacturing processes
Different manufacturing processes are often used to reduce the diameter to the specified smaller diameters, but most commonly employed method is turning process, in which the chamfered ends and reduction of the diameter of the shaft are usually performed/cut using the lathe. In this process a cutting tool/cutter with a single cutting edge is used to remove excess material from a rotating work-piece to generate a cylindrical shape. The speed motion is provided by the rotating work-piece and the feed motion is achieved moving the cutting tool slowly in a direction parallel to the axis of rotation of the work-piece. The tool or cutter is made up of a hard material such as diamond, or even a hardened steel tips are often used. 9.1.1.1. Diameter reduction turning operation
Figure 42: Diameter reduction of the shaft
When the diameter of the shaft is reduced, the work piece is held in place using either a chuck or tip centres on both ends of the shaft. The cutting tool is normally set to shave off small material (depth of cut) up until the desired diameter is obtain, in this way there is no risk of blunting the tool.
MOX_410 [JUNE 2012] 9.1.1.2. Chamfer turning operation
Figure 43: Chamfering of the shaft ends
The chamfering turning process requires a cutting tool with the required angle as depicted in the figure above. The shaft is held in place by a spindle with a chuck attached to it. Other methods for holding the work pieces is by three jaw chuck, four jaw chuck, collet or dog. As the work piece is rotated, the cutter is fed to the piece by an automatic feeding mechanism. 9.1.1.3. Connection holes in the shaft
The bolt holes for connections are cut using drilling operation. During this process the work piece is held stationary by clamping and the drill is rotated. Depending on the type of holes, the drilling process can take other machining processes such as reaming, tapping, counter-boring, centre drill, or spot facing. 9.1.1.4. Ends straightening
Both ends of the shaft will require straightening and making sure they are perpendicular to shaft length, and that they are parallel to each other. A process suitable for this operation is milling, in which a rotating tool with multiple cutting edges is gradually fed across the work-piece to generate a plane (straight surface). 9.1.1.5. Manufacturing schedule for valve shaft
Table 21: manufacturing schedule for valve shaft
Schedule 1. 2. 3. 4. 5. Large diameter Small diameter Straight faces at ends Bolt holes for disc connection Screw holes for securing bush
Type of operation Turning operation Turning operation Milling operation (face milling) Drilling operation Drilling operation (tapping)
MOX_410 [JUNE 2012] 9.1.2. Valve body manufacturing process The dimensions of the body of the valve were determined to be as follows: Internal diameter: Width: Shell thickness: 2700 mm 800 mm 15 mm
The manufacturing processes selected for this component are based on the availability of the workshops or facilities capable of housing such an enormous valve. The body will be fabricated from a number of segments of metal plates (sheet metals). The number of the segments is dependent on the diameter of the valve and the length of plates that are commercially available. In this case, two plate segments will suffice. 9.1.2.1. Cutting plates into shapes
The first operation will be cutting the plates to sizes, and preparing the edges for welding. The cutting operation can be achieved by thermal or mechanical means. An oxygen cutting torch is usually used to cut the plates to desired lengths, after which the slag and discolouration can easily be removed mechanically.
Figure 44: oxygen cutting of plates into desired lengths
9.1.2.2.
Connections for bearing housing
The shaped plate segments will be holed in the centre using a punch. The punching operation is the cutting of a sheet metal along a closed outline (produce a hole) in a single step to separate the piece (slug) from the surrounding stock. The remaining stock is the desired part.
Figure 45: a holed plate segment for bearing housing connection
MOX_410 [JUNE 2012] 9.1.2.3. Two circular segments
The prepared plate segments are rolled into circular arcs using a tube forming process (bending operation). In tube forming, a plate segment is placed over a die cavity and then pushed into the opening with a punch. This process is relatively easy except that very large dies will have to be constructed.
Figure 46: tube forming of the plate segments
9.1.2.4.
Plate segments joining
The two circular plates will be joined by weldments. After the plates have been rolled, they are tackwelded into a cylinder course as figure below. The welding is usually performed by an automatic machine. The joints are welded on the inside and outside by one pass of the machine. After welding, the joint should be radiographed to detect defects in the welds.
Figure 47: workshop fabrication of large diameter cylinders [22]
9.1.2.5.
Manufacturing schedule of valve body
In summary, the manufacturing schedule of the valve body includes cutting the plates to exact dimensions, preparing the edges for welding, pressing and rolling the plates to the required radius, and welding the plates together.
MOX_410 [JUNE 2012] 9.1.3. Manufacturing processes for the whole product The following list of manufacturing processes is for components and/or structures that would require manufacturing in a workshop or similar facility. Repetitive manufacturing processes such hole drilling are not mentioned. The standard parts can be purchased over the counter.
Table 22: manufacturing processes
Component Shaft Valve body disc Bearing housing Seat holder Support structure Torque unit Connection flange
Processes involved Turning Milling (facing) Cutting, Tube forming, Pressing / rolling Welding and radiography Sand casting, Cutting Turning Extrusion, Rolling Cutting and bending, Welding Casting, Cutting and bending Casting
MOX_410 [JUNE 2012]
9.2.
Maintenance Analysis
Maintenance is one of the major parts of designing any product. Unforeseen failure of the valve can have a substantial impact on the generation and revenues because of the extended forced power outage. The maintenance of a cut-off valve is outlined as follows. 9.2.1. Component failure Maintenance of most butterfly valves is generally limited to actuators, seats and shaft seals. During the design phase, it was observed that shafts and bearings have a certain life expectancy; therefore there should be regular inspections and possible replacements, as specified. The design of the valve in this report will allow field adjustment or replacement of the rubber seat whenever excessive leakage past the disc occurs. Typical maintenance of butterfly valve is in the area of shaft seals and actuators. Seal or seat leakage, broken parts, and hard operation should be attended to by the maintenance crew as soon as possible after the first detection is reported. The maintenance crew should take a full complement of spare parts whenever any repairs are done in the field and they should ensure they review the valve manufacturers maintenance instructions prior to any work wherever applicable. Prior to any corrective maintenance, provision should be made to cut-off the water flow and isolate the valve form line pressure. If the required maintenance require the removal of the valve for repairs, all parties should be notified that the water line is out of service and after the repairs are done and the valve re-installed, the same parties should be notified that the line is indeed in service. 9.2.2. Protection from the environment The cut-off valve will be used for cutting off water in a hydropower station and will be operating in an above-ground location/area near a dam. The interior and exterior surfaces should be coat protected from damages such as corrosion. The interior of the valve shall be coated with epoxy or any other similar coats. The exterior of each valve, except the flange face should be coated with a suitable metal primer to a dry-film thickness no more than 0.12 mm (ANSI, 2006). Other external coating that may be considered for corrosion protection against acidic soils, water contaminated by certain waste. Polyethylene sleeving Polyurethane coating Epoxy coating Asphalt varnish 9.2.3. Protection of human lives Failure of cut-off valve could pose a huge threat to human lives and could damage expensive equipment. Hence, it is paramount to develop and maintain an updated condition assessment of the cut-off valves installed in a plant and plan accordingly. An assessment provided by Hydropower Advancement Project can be used for any plant with major valve systems.
MOX_410 [JUNE 2012]
9.3.
Reliability analysis
The design specifications states that the large cut-off valve should have a reliability rating of three out of five or better. These rating equate to reliability percentage of 50% or more meaning that all the components of the valve should have at least 50% chance that they perform the expected proper functions without failure. According to Shigley et al, the reliability of a system is expressed as: =1 ; [0,1]
The designed cut-off valve has a total of 38 different parts. From the equation of reliability, it can deduced that if none of these parts fails while the valve is operation, then the designed product is 100% reliable. However, that can only happen in unreal situations.
9.4.
Cost Analysis
Cost of the final product is analysed in this subsection. Cost analysis gives an indication for the good heard for the manufacturing of the product. The amounts provided herein, are approximated cost of the final product. The total costs excludes the cost of the motor for actuation, hand-wheel manual actuation, transportation from various workshops and to the final destination of the finished product. The table below summarises the cost of each unit of the large cut-off valve.
MOX_410 [JUNE 2012]

Table 23: final product cost estimates
Component Valve Body Bearing Housing 1 Bearing Housing 2 Support Structure Seat Rubber Seat Liner Seat Holder Disc Hub seat Shaft End Connection Flange Axial Bearing End Plate Gasket End Plate Flanged Bush Packing Follower Packing Holder Torque unit studs Washer ISO 7411bolts and nuts ISO 1712 bolts and nuts ISO 8676 Screws TOTAL COST
Material 16x800x4400 mm plate 750x420 mm metal rod 650x420 metal rod 50x1400x2600 plate 60x60x4400 mm Raw material-ductile iron 10x80x2200 mm plate 450x20 mm 280x3800 metal rod Special order
Unit price 5325. 75 2000 1800 2600 450 750 600 150 2750 1400 180 150 220 450 270 180 3700 60
Manufacturing 5000 1200 1200 800 200 340 350 100 1200
Quantit y 1 1 1 1 1 2 2 2 1 2 1 1 1 2 1 1 1 4
Total Amount 10325.75 3200 3000 3400 750 2180 1900 500 3950 2800 180 150 330 1300 470 280 5800 240 100 2000 1500 800 R 45155.75
650x40 mm metal plate Raw material iron 500x20 metal plate Raw material iron and 60 mm rods Steel 24 mm dia M30x350, M22x100 M24x150 M8x1.0x25
110 200 200 100 2100 -
MOX_410 [JUNE 2012]
10.
Conclusions and Recommendations
10.1. Conclusions
The purpose of the design project was to design a large cut-off valve to be used in isolation of turbines in hydroelectric power plants. The valve was design to be compatible with a 10MW water turbine operating under a 30m water head. Literature study was conducted focusing on the hydropower plant components; different types of valves used such plants; cut-off valves and flow rate determination from the known output power and head. From the literature study, it was found that butterfly valves are more compact, simple to design with limited resources. Different concepts were evaluated for each of the subsystems. One of the major consideration factors for the selection of the concepts used was cost, an attempt to make the valve more economical and thus favourable to be considered for manufacturing. A detailed design of the valve was undertaken. The nominal diameter of the valve was found to be very large. This fact meant that standard parts were not going to be an option as parts of the required sizes cannot be purchased over the counter, at best they can be specially ordered. The design was analysed in terms of manufacturing, maintenance, reliability, and overall cost.
10.2. Recommendations
Valves, similar to the butterfly valves, which are used during emergency situations, require rigorous testing before installation. Large companies utilise well-developed computer simulations for testing of such valve, before any work with regard to manufacturing commence. The butterfly valves normally allow field adjustment or replacement of the rubber seat whenever excessive leakage past the disc occurs. Typical maintenance of butterfly valve is in the area of shaft seals and actuators. Seal or seat leakage, broken parts, and hard operation should be attended to by the maintenance crew as soon as possible after the first detection is reported.
MOX_410 [JUNE 2012]
11.
[1]
References
[2] [3] [4] [5]
[6] [7]
[8] [9]
[10] [11]
[12] [12] [13] [14] [15] [16] [17]
Oklahoma water and wastewater utilities. 2012. AMERICAN Valves and Hydrants Support New Transmission Lines in Oklahoma City. [online]. Available: http://www.americanusa.com/industries/water-and-wastewater/water-treatment-plants/american-valves-andhydrants-support-new-transmission-lines-in-oklahoma-city Ball, B. E. et al. 2002. CASTI Guidebook to ASME Section VIII Div. 1 Pressure Vessels. 3rd Edition. CASTI Guidebook Series, vol. 4. Canada, CASTI. Klunne, W. J. 2012. Hydropower in South Africa. [online]. Available: http://www.microhydropower.net/rsa/ [08, March 2012] The World Bank group. 2009. Directions for hydropower. [Online]. Available: www.worldbank.org [08, March 2012] Woltz, C. 2011. South Africa and Lesotho building a 1.2 GW hydropower project. [online]. Available: http://www.renewbl.com/2011/08/15/south-africa-and-lesotho-building-a-1-2gw-hydropower-project.html [21, March 2012] Gulliver, j. S. & Arndt, E. A. 1991. Hydropower Engineering Handbook. New York: McGraw Hill International Hydropower Association, et al. 2000. Hydropower and the worlds energy future: the role of hydropower in bringing clean, renewable, energy to the world. Available at http://www.ieahydro.org/reports/Hydrofut.pdf [accessed on 19 March 2012] Gedeon, G. 1995. Engineering and Design: planning and design of hydroelectric power plant structure. Department of the army. US army corps of engineers. Washington DC. MESA Associates, Oak Ridge National Laboratory & US Department of Energy. 2012. Condition assessment manual: guide for control/shut-off valve condition assessment. Available at Harvey, A.2011. micro-hydro design manual: a guide to small-scale water power schemes. Warwickshire, UK: Practical Action Coleman, H. W, et al. 2004. Hydraulic design for energy generation. In: Hydraulic design handbook (chapter 8). [online]. Available at http://203.158.253.140/media/eBook/Engineer/Hydraulic%20and%20Pneumatic/Hydraulic%20Design%20Handbook/007144 9590_ar008.pdf Pool plaza swimming pool supplies.2012. Plumbing and valves. [Online]. Available: http://www.poolplaza.com/pool-school/plumbing_valves.shtml [2012, April 12] ADAMS Product Brochure. Built to meet critical requirements. [Online]. Available: http://www.adamsvalves-usa.com/brochures/Product_Brochure.pdf [2012, March 08] HEPP Rucr 1 Spherical valve DN 2000, Romania. [Online]. Available: http://www.ucmr.com/galerii/images/p57.jpg [2012, March 08] DeZurik, inc. 2011. Willamette ball and cone valves. Bulletin 2200/2600. [online]. Available: http://www.dezurik.com [2012, 12 April] Valmatic valve and manufacturing corp. 2010. Bulletin 2000-American BFV butterfly valve. [online]. Available: http://www.valmatic.com/butterflyvalves.html#IMs [2012, March 7] Howlitt, P. & Webster, V. 2012. Ductile Iron pipe. Winsen DCI piping systems. [Online]. Available: http://winsendci.co.za/DuctileIronPipe.html [25, May 2012] Forged Steel Flanges. Flange specification catalogue. [online]. Available: http://www.garthindustrial.com/pdf/FLANGE_SPECS.pdf 75 | P a g e Design of a large cut-off valve
MOX_410 [JUNE 2012] [18] [19] [20] ASM International handbook committee, 1995. Editor Davis, J. R. cast irons. 2th edition. Vesco Plastic Sales, Pty Ltd. 2012. The new advance bearing material. Vesconit hilube. [online]. Available: http://www.vesconite.com/prod/hilube.htm [29, May 2012] Wagner, D. Birt, J.A. & Snyder, M. 1996. Human factors design guide: for acquisition of commercial-off-the-shelf subsystems, non developmental items and developmental systems. FAA technical center. American National Standard Iinstitute (ANSI). 2006. Rubber seated butterfly valve. American water works association. ANSI/AWWA C504-06 United State Department of the Interior Bureau of Reclamation. 1986. A Water Resource Technical Publication: Welded Steel Penstocks. Engineering monograph No 3 Hydropower Advancement Project. 2012. Condition Assessment Manual Appendix 1.03 Guide for Control/Shut-Off Valve Condition Assessment. Revision 1.0
[21] [22] [23]
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12.
Annexure
12.1. Appendix A: Final models of the cut-off
Figure 48: Final model in closed position
Figure 49: Final model on an opened position
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Figure 50: Final model in a 45 degree open position
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12.2. Appendix B: Simulations using computer software Simulation of the valve disc
The valve disc is simulated using Simulation-Xpress, a software package in SOLIDWORDS. The simulation is performed to predict the deflection of disc subjected to uniform pressure. The most vulnerable and crucial part of the valve disc assembly was determined to be the half circle not supported by a shoulder and in order to prevent water leakage, it was necessary to minimise the total deflection loading due to pressure.
Figure 51: Valve disc with support bars welded onto the disc
Two simulations were performed; the first one was conducted on a plane valve disc without the support bars, and the second one was conducted on disc with support bars. It was found that the software did not have the material properties of 65-45-12 ductile iron, therefore the material properties closest to material used for disc construction were approximated by properties of malleable cast iron. The disc thickness of 60 was used
The bars are made of AISI 4340 normalised steel with properties; = 1110 , = 710 , = 205 , and = 0.32
Weld bead of 10 radius was used to attach the support bars to disc
The bar dimensions are 100 120
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Figure 52: Deflection of plane valve disc
Max stress: Max strain: Max displacement:
218 7.644 4 1.7351
Figure 53: Deflection of a valve disc with support bars
Max stress: Max strain: Max displacement:
164 6.883 4 3. 706
MOX_410 [JUNE 2012]
12.3. Appendix C: Detailed drawings

Design of A Large Cut Off Valve - Final Report

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SCHOOL OF ENGINEERING DEPARTMENT OF MECHANICAL AND AERONAUTICAL ENGINEERING DESIGN OF A LARGE CUT OFF VALVE

MOX_410 [JUNE 2012]

D. D. Jonker 28511141 Design MOX_410 Prof. N. J. Theron 04 June 2012

b|Page Design of a large cut-off valve

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i|Page Design of a large cut-off valve

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Dr S. Kaul Mr. P.R. De Wet Prof. N.D.L. Burger Mr. Plomp

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vi | P a g e Design of a large cut-off valve

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Key business goals

Assumptions and constraints

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Total Potential Percentage 93 percent 82 percent 79 percent 78 percent 75 percent 62 percent

Up to 20 kW 20-100 kW 100-1000 kW 1-10 MW >10 MW >10 MW >10 MW

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Figure 4: Schematic diagram of a typical hydropower plan

Dam and Reservoir

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Figure 6: Existing Katsu river dam in Lesotho (Woltz, 2011)

Powerhouse and its foundation

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Figure 7: Typical layout of penstock assembly

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MOX_410 [JUNE 2012] 4.2.1.1. Cut-off Valves

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Applications in relation to hydropower Diameters up to 750 mm

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Figure 10: Model of a spherical valve (DeZurik Inc, 2011)

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Applications in relation to hydropower Head > Disadvantages Poor throttling characteristics

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Figure 11: Model of cone valve (DeZurik Inc, 2011)

Power Calculations from Water

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Literature Study Conclusion

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System Level Diagram

Isolate turbine Emergency / maintenance

Long lifespan Non-corrosive Withstand varying loads