MOTORIZED GATE

VALVE

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 MOTORIZED GATE VALVE

MAIN PROJECT REPORT

Submitted in partial fulfillment of the requirement for the award of degree

of

Bachelor of Technology

in

Mechanical Engineering

Submitted by

AMIT JAISWAL (5808614)

Under the esteemed guidance of

DR. .........................,B.Tech, M.Tech.,Ph.D

Head of Department

Of

Mechanical Engineering

.................................. ENGINEERING COLLEGE

(Affiliated to ...................................... University)

2014-2015

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 TABLE OF CONTENTS

S.NO. TOPIC PAGE NO.

1 CANDIDATES DECLARTION 4
2 CERTIFICATE 5
3 ACKNOWLEDGEMENT 6
4 ROLE AND RESPONSIBILITIES 7
5 PERSONAL ENGINEERING ACTIVITY 8
6 ABSTRACT 9

7 OBJECTIVE 10

8 INTRODUCTION 11
9 MAIN COMPONENTS 16
10 TYPES OF MOTOR OPERATED VALVES 25
11 EXPERIMENTAL MODEL 27
12 APPLICAIONS 27
13 CONCLUSION 28

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 CANDIDATES DECLARTION

I hereby certify that the work which is being presented by Amit Jaiswal, Ajay
Singh Chauhan, Rajeev Kumar, Raman Kumar, Vijay Kumar in partial fulfillment
of requirement for the award of degree of B.Tech. in MECHANICAL ENGINEERING
submitted at KALPI INSTITUTE OF TECHNOLOGY under KURUKSHETRA
UNIVERSITY, KURUKSHETRA is an authentic record of my own work carried out
under the supervision of Er. Harish Kumar Sharma (HOD) and Er. Vikas Kunnar.

Project Member:

Amit Jaiswal [5808614]

Ajay Singh Chauhan [5808615]
Rajeev Kumar [5808608]
Raman Kumar [5808606]
Vijay Kumar [5808613]

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 CERTIFICATE

This is certify that the dissertation entitled MOTORIZED GATE VALVE by

RAJEEV KUSHWAHA, AMIT JAISWAL, SANDEEP ANAND SHARMA, MANISH KUMAR
TRIVEDI, PERVEZ KHAN,& DIVYANSH submitted to the Department of
mechanical engineering, Kalpi Institute Of Technology, Ambala in the partial
fulfillment of requirement for the award of Degree of Bachelor of Technology in
mechanical engineering is a record of bonafide work done by him under my
supervision and guidance during the session 2014-15. This work has not been
submitted to any other university or institute for the award of any degree or
diploma.

Head of department & project Guide

Mr.........................

Department of mechanical engineering

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 ACKNOWLEDGEMENT

First of all we would like to thank our project guide Mr. ......................
Assistant Professor, Mechanical engineering Department, Kurukshetra
University who has given valuable support during the course of our
project by clarifying our doubts and guiding us with her novel ideas.

We would like to thank Prof. .........................., Head of department,

mechanical engineering, Kurukshetra University.

We extend our sincere thanks to our Dean ....................................

Department of mechanical engineering for giving us this wonderful
opportunity to work in desired area of interest.

We extend our sincere thanks to all teaching staff of mechanical

engineering department, those who helped us in completing this
project successfully.

Lastly we also thank the people who directly or indirectly gave us

encouragement and support throughout the project.

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Role and Responsibilities

My roles and responsibilities includes:

Prepare a requirement document to reach expectations of project and to

come up with functionalities which are needed to be implemented.
Documentation of expected output for various aspects with accepted
margin error was also documented.
To design overall system based on workflow requirements.
Discussion with the project guide and Head of Department on ways to
improve the design and to optimize performance.
Choosing suitable components and methods based on the configurations
availability and requirements.
Testing and remedies.
Recommendations

As a trainee mechanical engineer, I wanted to work on a project work

that would showcase my engineering knowledge. I got the opportunity
to work on MOTORIZED GATE VALVE. This project was very important
as it evaluated my skills and talents in my company.

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PERSONAL ENGINEERING ACTIVITY

As a mechanical engineer, before undertaking any task I checked the

feasibility of the project. In this project, my role is as team members.
This report provides an insight into the design and fabrication of a
MOTORIZED GATE VALVE.

I wanted to know more details of the project before commencing;

hence, I researched the topic thoroughly by referring to journals and
articles online. Additionally, I obtained more information by taking
references about the topic.

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 ABSTRACT

A device for locking a motor driven valve or cock to hold it in an open or closed
position selectively. A variable reluctance step by step motor is coupled to the
valve through a resilient element and is speed controlled from a sensing unit
which applies a holding current to the motor. A coincidence sensor is fed pulses
from two position sensors responsive to magnetic changes.

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OBJECTIVE

Identify common valve types and their typical service applications.

Describe the mechanical components that make up rising-stem valves.
Describe the mechanical components that make up rotating-stem valves.
Describe the major electrical and mechanical components that make up
common motor actuators.
Describe the electrical and manual modes of operation of motor actuators and
trace the path of the rotational forces through the device.

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INTRODUCTION

A motorized valve is a valve type that use an electric motor to open or close its
mechanism. This type of valve is ideally suited to very large valve types or remote
fluid control applications such as aircraft deicing, agricultural irrigation, and
automated fire suppression. Most valve types are suited for motorized
applications with some commonly used types being gate, ball, and butterfly. The
motorized valve is also well suited to remote flow control applications where
system inputs involve incremental valve operation. The internal fluid control
mechanisms of motorized valves are generally identical to their manual
counterparts; valve actuation inputs are the only difference between the two.

Valves play an integral role in fluid flow circuits ranging from the garden hose to
hydroelectric power generation systems. Valve actuation can, however, present
logistic problems when valves are too large to be practically opened or closed by
hand, are in remote, inaccessible locations, or have to operate during periods
when plants or installations are unmanned. The answer to these problems is the
use of the motorized valve. This type of valve functions in exactly the same
fashion as a manual variety with the exception of being actuated by an electric
motor. This type of valve can be remotely opened or closed by an operator or by
inputs from an automated system.

Motorized valves typically feature an electric motor that drives an advance

mechanism through a gear train to open or close them. The particular advance
mechanism depends on the type of valve. Vertical travel valves such as gate or
sluice valves usually use a lead screw mechanism that lifts or drops the gate plate
and are usually found in larger systems such as water mains. Globe valves also use
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a screw advance mechanism to position the tapered plug which controls the fluid
flow in high precision metering applications.

Rotary or quarter turn motorized valves are the valve type with the quickest
actuation times and typically use a cam or central spindle advance mechanism.
These valves are among the most common motorized valve types and include ball
and butterfly valve varieties. These valves are not suitable for flow control but do
feature the best sealing characteristics of all the valve types. They are commonly
used on high pressure fuel lines and on aircraft deicing systems.

Internally the motorized valve is generally identical to a manual valve of the same
type. The only physical difference between the two is the inclusion of a motor and
gear train assembly. Motorized valve mechanisms are prevented from advancing
too far by using a set of electrical limits which cut the motor supply when a valve
is either fully opened or closed. When the valve needs to be adjusted again, the
motor's direction is simply reversed to turn the valve in the opposite direction.

An MOV is a combination of two separate devices, usually provided by two

separate manufacturers.

Valve Assembly a mechanical device to optimize a desired fluid control

function, such as isolation or throttling.
Actuator an electrical/mechanical device used to position a valve assembly
from a remote location.

The basic parts of a valve assembly have common nomenclature regardless of the
type of valve.

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valve body, bonnet, disc (pressure boundary)

seat, stem, and yoke

Valve Assembly Basic Parts

Process plants consist of hundreds, or even thousands, of control loops all

networked together to produce a product to be offered for sale. Each of these
control loops is designed to keep some important process variable such as
pressure, flow, level, temperature, etc. within a required operating range to

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ensure the quality of the end product. Each of these loops receives and internally
creates disturbances that detrimentally affect the process variable, and
interaction from other loops in the network provides disturbances that influence
the process variable.
To reduce the effect of these load disturbances, sensors and transmitters collect
information about the process variable and its relationship to some desired set
point. A controller then processes this information and decides what must be
done to get the process variable back to where it should be after a load
disturbance occurs.
When all the measuring, comparing, and calculating are done, some type of final
control element must implement the strategy selected by the controller. The
most common final control element in the process control industries is the
control valve. The control valve manipulates a flowing fluid, such as gas, steam,
water, or chemical compounds, to compensate for the load disturbance and keep
the regulated process variable as close as possible to the desired set point.
When we talk about control valves or valves , we are referring to a control valve
assembly. The control valve assembly typically consists of the valve body, the
internal trim parts, an actuator to provide the motive power to operate the valve,
and a variety of additional valve accessories, which can include positioners,
transducers, supply pressure regulators, manual operators, snubbers, or limit
switches.

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Control Valves
The control valve regulates the rate of fluid flow as the position of the valve plug
or disk is changed by force from the actuator. To do this, the valve must:
Contain the fluid without external leakage.
Have adequate capacity for the intended service.
Be capable of withstanding the erosive, corrosive, and temperature influences
of the process.
Incorporate appropriate end connections to mate with adjacent pipelines and
actuator attachment means to permit transmission of actuator thrust to the
valve plug stem or rotary shaft.
Many styles of control valve bodies have been developed through the years.
Some have found wide application, others meet specific service conditions and
are used less frequently. The following summary describes some popular control
valve body styles.
The control valves can be broadly classified into two types
1. Linear Motion Valves
2. Rotary Motion Valves
These are further classified into the different valves which perform the respective
type of fluid motion. The classification can be seen in the following table :

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Classification Of Different types of Control Valves

MAIN COMPONENTS:-

FRAME

WIPER MOTOR

BALL VALVE

CRANK

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WIPER MOTOR:

BALL VALVE:

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Working:

Fig shows a ball valve consisting of a spherical ball located between two sealing
rings in a simple body form. The ball has a hole allowing fluid to pass through.
When aligned with the pipe ends, this gives either full bore or nearly full bore
flow with very little pressure drop. Rotating the ball through 90 opens and closes
the flow passage. Ball valves designed specifically for control purposes will have
characterized balls or seats, to give a predictable flow pattern.

Ball valves are an economic means of providing control with tight shut-off for
many fluids including steam at temperatures up to 250C (38 bar g, saturated

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steam). Above this temperature, special seat materials or metal-to-metal seatings
are necessary, which can be expensive. Ball valves are easily actuated and often
used for remote isolation and control. For critical control applications, segmented
balls and balls with specially shaped holes are available to provide different flow
characteristics.

Actuators

The operation of a control valve involves positioning its movable part (the plug,
ball or vane) relative to the stationary seat of the valve. The purpose of the valve
actuator is to accurately locate the valve plug in a position dictated by the control
signal.

The actuator accepts a signal from the control system and, in response, moves the
valve to a fully-open or fully-closed position, or a more open or a more closed
position (depending on whether 'on / off' or 'continuous' control action is used).

There are several ways of providing this actuation. This Tutorial will concentrate
on the two major ones:

1. Pneumatic.

a) Piston actuators

b) Diaphragm actuators

2. Electric.

a) VMD ( Valve Motor Drive )

b) Modulating

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Pneumatic Actuators

Piston Actuators:

Piston actuators are generally used where the stroke of a diaphragm actuator
would be too short or the thrust is too small. The compressed air is applied to a
solid piston contained within a solid cylinder. Piston actuators can be single acting
or double acting, can withstand higher input pressures and can offer smaller
cylinder volumes, which can act at high speed.

Diaphragm Actuators

Diaphragm actuators have compressed air applied to a flexible membrane called

the diaphragm. Figure 6.6.2 shows a rolling diaphragm where the effective
diaphragm area is virtually constant throughout the actuator stroke. These types
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of actuators are single acting, in that air is only supplied to one side of the
diaphragm, and they can be either direct acting (spring-to-retract) or reverse
acting (spring-to-extend).

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Electric Actuators

VMD ( Valve Motor Drive )

This basic version of the electric actuator has three states:

1. Driving the valve open.

2. Driving the valve closed.

3. No movement.

Figure below shows the VMD system where the forward and reverse travel of the
actuator is controlled directly from any external 3-position or two 2-position
switch units. The switches are rated at the actuator voltage and may be replaced
by suitable relays.

Limiting devices are fitted within the VMD actuators to protect the motors from
over-travel damage. These devices are based on either the maximum motor
torque or physical position limit switches. Both devices stop the motor driving by
interrupting the motor power supply.

Position limit switches have the advantage that they can be adjusted to limit
valve strokes in oversized valves.
Torque switches have the advantage of giving a defined closing force on the
valve seat, protecting the actuator in the case of valve stem seizure.
If only position limit switches are used, they may be combined with a spring-
loaded coupling to ensure tight valve shut-off.

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A VMD actuator may be used for on/off actuation or for modulating control. The
controller positions the valve by driving the valve open or closed for a certain
time, to ensure that it reaches the desired position. Valve position feedback may
be used with some controllers.

Modulating

In order to position the control valve in response to the system requirements a

modulating actuator can be used. These units may have higher rated motors
(typically 1 200 starts/hour) and may have built-in electronics.

A positioning circuit may be included in the modulating actuator, which accepts

an analogue control signal (typically 0-10 V or 4-20 mA). The actuator then
interprets this control signal, as the valve position between the limit switches.

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Motor Operated Valve (MOV) is an important item of Plant & Piping system.
These valves are generally of large size and are used for different applications
such as Pump discharge etc. Motor Operated Valves are often called as On-Off
valves as the motors serve the purpose of fully opening or fully closing valves in
pipelines. For example, cooling water lines, process pipelines where controlling of
fluid is not required, motor operated valves can be used to fully allow or fully stop
the fluid flow. These valves are not used for throttling purposes as they serve
mainly On-Off service application.

Motor operated valves can be of various types e.g. Gate/ Ball/ Butterfly etc. with
actuator control. Design of Motors and valves can be different. An electric motor
is mounted on the valve and geared to the valve stem so that when the motor
operates the valve will open or close. For this MOV, motor operated with actuator
control from local panel or, from control room is required. There is a requirement
of co-ordination among Piping-Electrical-Instrumentation-Process engineers and
vendor for design and procurement of such motor operated valves.

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TYPES OF MOTOR OPERATED VALVES:-

Motorized control valve can be classified into three types. However it must be

noted that the main application of motorized valves are for flow control and flow

isolation.

Open/close valves - used to automate manual open close valves Examples

include, pump discharge / suction valves, boiler feed water isolation valves, drum

vent valves, product line valves etc.

Inching valves - used were some degree of control. Example a gradual opening

and closing is required, applications include, reflux lines, boiler start up vent,

boiler IBD valves, boiler main steam valves etc.

Precision flow valves - this is a precision inching valve, in inching valve the motor

operates in steps configured in the controller, e.g. 5%, 10% opening steps. In

precision flow valves, a continuous control is enabled by the use of proper

feedback from the field to the controller which is not usually found in other motor

operated valves. An example is steam injection valve / water injection valves used

in GT for Nox control.

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Key differences between control valves and motor operated

on/off valves:-

Control valves have a faster response as compared to the motorized valves.

Control valves usually have an analog control element, while the motorized

operated valves have a digital control element.

Control valves can be used for any type of control, pressure control, flow

control, temperature control etc while motorized valves are usually (if not

always) used for flow control.

Control valve usually are used in closed loop control, while motorized valves

are predominantly open loop (with the exception of precision flow control

valves)

Control valves are used for precision control. However motorized valves are

not usually used for precision control.

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EXPERIMENTAL MODEL:-

APPLICATIONS:-

Whenever frequent operation is required.

Valves located in remote, inaccessible or hazardous places.

Motorized control valve / Motor operated valves are usually for full open and full

close applications. However there are places where they are used for position

control as well.

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CONCLUSION:-

After completing the project, conclude that our project is simple in construction

and compact in size for use. Manufacturing of machine is easy and cost of the

machine is less.

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