Fpd Assignment (2)

8/8/2019 Fpd Assignment (2)

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FPD ASSI

BY:

Sainath.A.Jain

Ankit Baheti

Vidya T.K

Ashmita ghoshArpita


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Valves are mechanical devices designed to direct, start, stop, mix or

regulate the flow, pressureor temperature ofa process fluid. Thecommon types of valves available are gate valves, globe valves,butterfly valves etc. the materials commonly used for construction are

iron, steel, plastic, brass or a mixture of special alloys.

According to their function valves may be classified as on-off valves,non-return valves, and control valves

The on-off valves are used to start or stop the flow through the

process. EXAMPLE: Gate valves and pressure relief valves

The non-return valves allow the fluid to flow in one particular

direction only.

The control valves are used to regulate flow, temperature or

pressure through a system.


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The selection of the valve body material is usually based on pressure,temperature, corrosive properties and erosive properties of the flow media. Also

the choice of the materials depends on economic factors. Majority of control

valves involve non corrosive fluids at reasonable temperatures and pressure.

Therefore cast iron and cast carbon steel are most commonly used valve body

materials as it has a provision for repacking under pressure.

High lift of the seat is available to avoid any obstruction in the flow

Sturdy & bigger wheel provided to give sufficient torque for easy operation

Minimum pressure drop inside the body due to streamlined body design

Accurate Pressure and temperature for 200 mm valve

Comes in Straight / Right Angle Pattern

Maximum Steam Working Pressure: 13 Kg/ square cm Gauge

Maximum Working Temperature : 220 degree C

Size Range:15mm to 200mm


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he C.I. steam stop valve body has a bell-shaped configurati

nnular seating surface and includes a servo piston component o

T on terminating in an

a perating in a cylinderand an associated pilot valve for controlling steam entry into the cylinder from the

steam chamber. It is used in controlling steam entry into the cylinder from the steam

chamber by way of a longitudinal bore through the spindle and valve head.

C.I. STOP VALVE

Working Pressure :

Steam Pressure upto 13 kg /cm2 &

Temperature upto 220oC

Testing Pressure :

26kg./cm2 Hydraulic


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MaterialComponents Standard

Body, Bonnet, Gland,

Hand wheel,Cast Iron IBR 86 to 93 Gr. A

Stem, Disc Nut, Disc,

Body Seat RingStainless Steel A ISI-410

Gasket CAF IS: 2712

Gland Packing Graphite Asbestos -

Bolts, Nuts, Studs,

WashersCarbon Steel -

Yoke Bush Aluminium Bronze -


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Body and bonnet The main parts of a valve are the body and the bonnet. These

two parts form the casing that holds the fluid going through the

valve. The bonnet is the casing through which the stem passes

and that forms a guide and seal for the stem.


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Valve bodies are usually metallic. Brass, bronze, gunmetal, cast iron, steel, alloy steelsand stainless steels are very common.

Seawater applications, like desalination plants, often useduplex valves, as well as super duplex valves, due to theircorrosion resistant properties, particularly against warmseawater.

Alloy 20 valves are typically used in sulphuric acid plants,

whilst monel valves are used in hydrofluoric acid (HF Acid)plants.

Hastelloy valves are often used in high temperatureapplications, such as nuclear plants, whilst inconel valves areoften used in hydrogen applications.

Plastic bodies are used for relatively low pressures andtemperatures.

PVC, PP, PVDF and glass-reinforced nylon are commonplastics used for valve bodies


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A bonnet acts as a cover on the valve body. It is

commonly semi-permanently screwed into the valve

body.

During manufacture of the valve, the internal parts are

put into the body and then the bonnet is attached tohold everything together inside.

To access internal parts of a valve, a user would take

off the bonnet, usually for maintenance.

Many valves do not have bonnets; for example,

plug usually do not have bonnets.


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Ports are passages that allow fluid to pass throughthe valve. Ports are obstructed by the valvemember or disc to control flow. Valves most

commonly have 2 ports, but may have as many as 20.

The valve is almost always connected at its ports to pipesor other components. Connection

methods include threading,

compression fittings, glue, cement,

flanges, or welding.


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A disc or valve member is a movable obstruction insidethe stationary body that adjustably restricts flow

through the valve. Although traditionallydisc-shaped, discs come in variousshapes.

A ball is a round valve member with one or more pathsbetween ports passing through it. By rotating the ball flow can

be directed between different ports. Ball valves usespherical rotors with a cylindrical hole drilled as a fluid

passage.

Plug valves use cylindrical or conically tapered rotorscalled plugs .Other round shapes for rotors are possible as wellin rotor valves, as long as the rotor can be turned insidethe valve body.

However not all round or spherical discs are rotors; for example, a ball check valve uses the ball to block reverse flow,

but is not a rotor because operating the valve does not involve


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rotation of the ball.


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DISC


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The seat is the interior surface of the body which contacts the disc

to form a leak-tight seal. In discs that move linearly or swing on ahinge the disc comes into contact with the seat only when the valve

is shut. In disks that rotate, the seat is always in contact with the

disk, but the area of contact changes as the disc is turned. The seat

always remains stationary relative to the body.

Seats are classified by whether they are cut directly into the body,

or if they are made of a different material:

Hard seats are integral to the valve body. Nearly all hard seated

metal valves have a small amount of leakage.

Soft seats are fitted to the valve body and made of softer materialssuch as PTFE or various elastomers such as NBR, EPDM,

or FKM depending on the maximum operating temperature.


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The stem transmits motion from controlling device to the disc.

The stem typically passes through the bonnet when present.

In some cases, the stem and the disc can be combined in one

piece, or the stem and the handle are combined in one piece.

The motion transmitted by the stem may be a linear force, a

rotational torque, or some combination of these.

The valve and stem can be threaded such that the stem can bescrewed into or out of the valve by turning it in one direction or

the other, thus moving the disc back or forth inside the body.


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Valves whose disc is between the seat and the stem and where

the stem moves in a direction into the valve to shut it arenormally-seated orfront seated.

Valves whose seat is between the disc and the stem and where

the stem moves in a direction out of the valve to shut itare reverse-seated orback seated.

These terms don't apply to valves with no stem or valves

using rotors.


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The internal elements of a valve are collectively referred to as a

valve's trim.

According to API Standards 600, "Steel Gate Valve-Flanged

and Butt-welding Ends, Bolted Bonnets", the trim consists of

stem, body seating surface, gate seating surface, bushing

or a deposited weld for the backseat and stem hole guide, and

small internal parts that normally contact the service fluid,

excluding the pin that is used to make a stem-to-gate

connection (this pin shall be made of an austenitic stainlesssteel material).


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S flow layout is a form of product layout. In thislayout various facilities such as machines,equipment, work force etc. are located as per sequence of operation on parts. This type of layout is preferred when production iscontinuous, part variety is les productionvolume is high and part demand is relatively

stable.


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A

Less WIP inventory as the flow of material is

continuous along a line.

The flow of material is smooth and continuous.

Compared to process layout it requires less space

for same volume of production.

The throughput time (or product cycle time) is

less as compared to process layout.


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Simple production planning and control and

better coordination of different activities may

be achieved.

Conveyorised material handling or automationin the material handling is cost effective as

the flow of material is well know.

The skill level of workers may be lesser as a

particular worker has to do a particular operation which seldom changes due to

standardized product line.


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Change in product design is difficult to

accommodate.

Product variety is very much limited.

Breakdown of a particular machine line haltsthe production output.

Capital investment in machine may be higher as

compared to layout as duplication of machine in

a line may be needed.

The flexibility to increase the production

capacities may be limited.


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Economic batch quantity (EBQ)

Formula:

EBQ=sqrt(2AS/C)

Where A=demand S=set up costs

C=holding costs

Thus EBQ=sqrt(2*10000*1500*3)/(1500)) =245 units

No. of cycles = 10000/245=40 cycles


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A total of 6 components are required to make a steam

stop valve

Here we assume that 3 components are procuredthrough outsourcing and the other 3 aremanufactured in-house


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Component

Number

Required

production

rate(Pij)

Standard

production

rate(1/Tij)

Hours per

month

(Hij)

1 15000 110 125

2 12000 90 125

3 10000 70 125


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The number of machines required is given by theformula:

n Mj=Pij Tij/Hij

i=1

where:

Pij=desired production rate for product i on m/cj(pieces/production)

Tij=production time for product i on m/c j

Hij=no.of hours in production period available forproduction of product i on m/c j

n=Number of products


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Mj

Mj= (15000/(125*110)) + 12000/(125*90))

+(10000/(125*70))

Thus Mj=1.09+1.06+1.14 =3.29

= 4 machines

Mj=4 machines


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M/c no. Area Quantity Producti

onrate

m/c

code

Area(s

q.m)

1 2.5*.8 1 75 A 2

2 5*1.5 1 80 B 7.5

3 6*.75 1 75 C 4.5

4 3*.75 1 70 D 2.25

Base area =16.25 sq.m


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From To From To WIP

A D 75 70 5

B D 80 70 10

C D 75 70 5

Total WIP=20 units/hr


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Aisle area=1 m (because of light material

handling)

Base area=16.25 sq.m Working space and tool area=B=16.25 sq.m

Tool crib area=.2*B=.2*16.25 =3.25 sq.m

Maintenance area=3.75 sq.m

Supervisory area=2.5*2 =5 sq.m


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Thus WIP=20 units/hr

Dimensions of product=60*300 sq.mm

Corresponding area=20*60*300 sq.mm/hr

=360000 sq.mm/hr or

0.36 sq. m/hr

Corresponding area/week on single

stacking=(.36*8*3*6)=51.84 sq.m [as 3 shifts/day;8 hrs/shift;6 days a week)


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Executive chamber=4*5*2=40 sq.m(for 2executives)

Office area=4*15=60 sq.m

Conference room=50 sq.m (upto 15 people)

Generator room: Main area =15 sq.m for100kva

Total administrative area=150 sq.m


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Inspection area=.1625 sq.m

Internal access area=B=16.25 sq.m

Amenities=25 sq.m

Total shop floor area=138.7025 sq.m


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Fpd Assignment (2)

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