DESIGN AND ANALYSIS OF RAMS BOTTOM SPRING LOADED SAFETY VALVE

CHAPTER-1
INTRODUCTION

1.1 ABOUT CATIA AND ANSYS SOFTWARE

i. ABOUT CATIA
CATIA (computer-aided three-dimensional interactive application) is a multi- platform software
suite for computer-aided design (CAD), computer-aided manufacturing (CAM), computer-aided
engineering (CAE), PLM and 3D, developed by the French company Dassault Systems. This document
discusses concepts and terminology used throughout the CATIA application. It familiarizes you with
the commonly used functions of CATIA.

➢ Concepts

Surfacing
Surface modeling is the very important application of the CATIA here is used to makes the
model in surface having no thickness. It is the only surface of the any solid object Or we
can make the solid object by making first the surface design of the object. So the surfacing
shows the actual view or shapes and size of the object. Here we are using SKETCH TRACESS to
make the design of the any component. It is a technique in which where the help of the
pictures we can make the surface body of the object.

3D Design
CATIA uses a 3D design approach. As you design a part, from the initial sketch to the final
result, you create a 3D model. From this model, you can create 2D drawings or mate
components consisting of parts or subassemblies to create 3D assemblies. You can also
create 2D drawings of 3D assemblies. When designing a model using CATIA, you can visualize
it in three dimensions, the way the model exists once it is manufactured.

Assembly Definition
An assembly is a collection of related parts saved in one CATIA document file with CAT
Product extension Assemblies.

Drafting
You create drawings from part or assembly models. Drawings are available in multiple views
such as standard 3 views and isometric views (3D). You can import the dimensions from the
model document and add annotations such as datum target symbols

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i. ABOUT ANSYS

The ANSYS Mechanical software suite is trusted by organizations around the world to rapidly
solve complex structural and thermal problems with ease. Structural mechanics solutions from
ANSYS provide the ability to simulate every structural aspect of a product, including nonlinear static
analysis that provides stresses & deformations, modal analysis that determines vibration
characteristics, through to advanced transient nonlinear phenomena involving dynamic effects &
complex material behavior.

➢ CONCEPTS

ANSYS Mechanical
ANSYS Mechanical software offers a comprehensive product solution for structural
linear/nonlinear and dynamics analysis. The product offers a complete set of element
behavior, material models and equation solvers for a wide range of engineering problems.
In addition, ANSYS Mechanical offers thermal analysis and coupled-physics capabilities
involvingacoustic, piezoelectric, thermal-structural and thermal-electric analysis.

ANSYS Structural
ANSYS Structural software addresses the unique concerns of pure structural
simulations without the need for extra tools. The product offers all the power of nonlinear
structural capabilities in order to deliver the highest-quality, most reliable structural
simulation results available. ANSYS Structural easily simulates even the largest and most
intricate structures.

ANSYS Professional
ANSYS Professional software offers a first step into advanced linear dynamics and
nonlinear capabilities. Containing the power of leading simulation technology in an easy-
to-use package, ANSYS Professional tools provide users with high-level simulation
capabilities without the need for high-level expertise. The package comes complete with a
full contingent of linear elements, significant nonlinearities, the ability to solve complex
assemblies, and the most requested set of solvers.

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1.2 HISTORY

[1.1 Denis Papin (1647-1710)] (1.1 Papin’s Bone Digester)

The first safety valve was invented in 1681 by Denis Papin, a Frenchman, who was born
at Blois, France in 1647. He commenced his experiments on the phenomena of steam in July 1676,
at London under Robert Boyle, the distinguished Irishman who founded the Royal Society of
London. About 1680, Papin brought out a little steam apparatus called, “Papin’s Bone Digester,” for
softening animal bones.

England’s Charles II ordered Papin to make a digester for his laboratory at Whitehall, and
the invention excited much interest. By means of this steam-pressure cooking machine, delicious
jellies were made from beef, mutton and other bones.

In 1855, John Rams bottom, later locomotive superintendent of the London and North
Western Railway, described a new form of safety valve intended to improve reliability and
especially to be tamper-resistant.
1.3 AIM OF PROJECT

As students of mechanical engineering I have studied in the detailed fundamentals of

engineering , manufacturing processes, machine design, strength of material, metallurgy, maintains,
costing, management, turbo machinery, industrial fluid power etc. I have been given opportunities to
exhibit our learning abilities through this project work.

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During the project work most aspect of engineering fields are covered in master course in
CAD/CAM in Indo German tool room Aurangabad. The purpose of introduction of project is to
develop.

➢ Software knowledge and engineering concept.

➢ Process or product planning.
➢ Time management
➢ Team work.

1.4 THEORY

1.4.1 TYPES OF SAFETY VALVE

(1.4.1 Types of safety valve)

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1.4.2 DEFINATION OF VALVE AND SPRING LOADE SAFETY VALVE

A valve is device that regulates, directs or controls the flow of fluid (Gases, liquids,
fluidized solid, slurries) by opening, closing, or partially obstructing various passageways.

a spring loaded safety valve used especially on locomotives in which two valves
are pressed down by a single spring attached to a crosspiece prolonged to form a hand lever by
which the valves may be eased up to test their adjustment.

(FIG 1.4.1 Rams bottom spring loaded safety valve)

(FIG 1.4.2 Parts of Rams bottom spring loaded safety valve)

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1.4.3 CONSTRUCTION AND WORKING

Rams bottom safety valve is intended to improve the reliability and specially
to be temper resistance. A pair of plug valves were held down by common spring loaded
lever between them and single central spring. Various forms of Rams bottom safety valve
will be produced. Somewhere separate fittings to the boilers to the separate penetration and
others are U-shaped housing as we can see in this model this is U-shaped model fasten to the
single opening in the boiler shell.

U-shaped housing having flange coupling connection given mount to on the boiler
and for easy maintains. The eyebolt is mounted at the center space of valve upon which the
link is connected the link is having slot which allow the

1.4.3 Construction and working diagram

Spring to expand as the pressure acts on valve the valve gets open up and spring expand and
the pressure is distributed equally by this type of design and the pressure gets released. The
spring tension is important parameter for the working of rams bottom safety valve the lever
can also used to release the pressure manually the in boilers the flange size also vary with the
equipment these valves are called as safety valves or pressure valve. In this case the diameter
of housing and thickness of the housing plays a very crucial role in design of Rams bottom
safety valve.

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1.5 APPLICATIONS
1) Locomotives

(1.5.1 Locomotives applications)

2) In Industries to avoid blast in boiler due to excess pressure.

(1.5.2 Industrial boiler applications)

1.6 ADVANTAGES AND DISADVANTAGES

ADVANTAGES DISADVANTAGES
1) Accidents are avoided.
2) Easy to operate. 1) Maintains is hard
3) Loading and unloading possible. 2) Old mechanism
4) Small in size. 3) Not fully-automatic
5) Access is easy.
( 1.6 advantages and disadvantages)

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1.7 DIFFERENCE BETWEEN PRESSURE RELIEF VALVE AND SAFETY VALVE

PRESSURE RELIEF VALVE SAFETY VALVE
1. A relief valve relieves the pressure 1) A safety valve, on the other hand,
by relieving the fluid back into the relieves the pressure into the
system, to the low pressure side atmosphere i.e. out of the system.
e.g. the relief valves of a positive 2) Safety valve may not have an operator
on it to assist in opening the valve in
displacement pump.
response to a control signal.
2. A relief valve may have an operator 3) Safety valve opening will happen at
on it to assist in opening the valve after reaching the set
in response to a control signal pressure.
3. Relief valve opening is directly 4) Safety valve is set at 3% above the
proportional to the working pressure.
pressure rise. 5) Safety valve is used in a vapours or
4. Relief valve is set at 10% above steam system.
working pressure. 6) Safety valve releases the vapour or
5. Relief valve can be used in Fluid or steam in Atmosphere.
7) But in case of Safety valve when the set
compressed air system.
pressure is reached, the valve opens
6. Relief valve releases the fluid in almost fully. Generally it is set not more
such a way circulates in the system than 3% above of working pressure and
(suction line).But in case of it release the pressure up to not below
Compressed Air, it releases it to 4% of working pressure. Use on: Boiler,
atmosphere. super heater etc.
7. Opening of a relief valve is 8) A safety valve has a reservoir which
proportional to the increase in fluid stores the excess of fluid that flows
pressure. Its opening is not sudden, beyond the limit set.
but gradual if the pressure is 9) Safety valves are used when expensive
fluids are used.
increased gradually. Usually no
10) A safety valve is a control mechanism
immediate attention is required if that releases the pressure when it
the relief valve open. Use on: Air crosses a set threshold and then resets
bottle, hydrosphere tank, heat back to the original position. E.g. the
exchanger etc. valve on a pressure cooker or autoclave
8. a relief valve doesn't have a where you want to keep the contents
reservoir to store the fluid. at/under a specified pressure.
9. in the case of less valued fluids , a
relief valve is used.
10. A relief valve is a relief mechanism
to instantly relieve the pressure that
is triggered in extreme
circumstances when the pressure
has suddenly exceeded or is
approaching failure criteria for the
system itself, when materials
approach their yield limit and parts
can start breaking.

TABLE NO.1.7 diff. in pressure relief valve and safety valve

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CHAPETR -2

PROJECT PART AND DRAFTING

2.1 CATIA SOFTWARE MODEL AND DRAFTING

1. HOUSING

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2. EYE BOLT

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3. LINK

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4. VALVE SEAT

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5. VALVE

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6. PIVOT

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7. PIN

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8. SPLIT PIN

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9. LEVER

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10. SPRING

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11. WASHER

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12. LOCK NUT

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13. NUT

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14. ASSEMBLY

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15) EXPLODE VIEW

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CHAPTER NO-3
ANALYSIS

3.1 ASSUMPTIONS FOR ANALYSIS

▪ The load applied on lever by human hand is approximately 5 kg (49.033 N). But
this project designed for 3 kg (29.42 N).

▪ Materials used are cast Iron, stainless steel, structural steel etc.

▪ Comparison between two metals at various load condition is done and then
section carried out.

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3.2 ANALYSIS

1) HOUSING

Material Total deformation Equivalent stress/von Mises stress

Cast iron 7.8719E-10 0.00075369
Mild steel 4.6089E-8 0.00075369

• Equivalent stress (von Mises stress) in analysis for stainless steel value is same as
cast iron. But deformation in cast is low.
• Therefore cast iron is selected for making this part for assembly.

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2) EYE BOLT

Material Total deformation Equivalent stress/von Mises stress

Cast iron 0.019258 13.1624
Mild steel 0.018156 12.613

• Equivalent stress (von Mises stress) and total deformation in analysis for mild
steel value get small as compared with cast iron.
• Therefore mild steel is selected for making this part for assembly.

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3) LINK

Material Total deformation Equivalent stress/von Mises stress

Cast iron 9.920E-6 1.0132
Mild steel 9.7819E-6 1.0392

• Equivalent stress (von Mises stress) and total deformation in analysis for mild
steel value get small as compared with cast iron.
• Therefore mild steel is selected for making this part for assembly.

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4) VALVE SEAT

Material Total deformation Equivalent stress/von Mises stress

Cast iron 8.6684E-6 0.083164
Mild steel 8.8453E-6 0.083031

• Equivalent stress (von Mises stress) and total deformation in analysis for mild
steel value get small as compared with cast iron.
• Therefore mild steel is selected for making this part for assembly.

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5) VALVE

Material Total deformation Equivalent stress/von Mises stress

Cast iron 6.9225E-6 0.1764

• Standard material used for manufacturing of valve is gun metal or cast iron.
• This analysis is done with cast iron and get quite good result to use this part in
assembly.

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6) PIVOT

Material Total deformation Equivalent stress/von Mises stress

Cast iron 0.0006176 3.1148
Mild steel 0.0006176 3.1148

• Equivalent stress (von Mises stress) and total deformation in analysis for mild
steel value get equal to cast iron.
• Therefore any one of material is suitable.

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7) PIN

Material Total deformation Equivalent stress/von Mises stress

Cast iron 4.5154E-5 4.5674
Mild steel 4.5154E-5 4.5674

• Equivalent stress (von Mises stress) and total deformation in analysis for mild
steel value get equal.
• Therefore any one of material is suitable.

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8) SPLIT PIN

Material Total deformation Equivalent stress/von Mises stress

Cast iron 0.86593 1757
Mild steel 0.863001 1755.3

• Equivalent stress (von Mises stress) and total deformation in analysis for mild
steel value get small as compared with cast iron.
• Therefore mild steel is selected for making this part for assembly.

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9) LEVER

Material Total deformation Equivalent stress/von Mises stress

Cast iron 3.4435E-5 1.0324
Mild steel 1.9044E-5 0.57219

• Equivalent stress (von Mises stress) and total deformation in analysis for mild
steel value get low as compared with cast iron.
• Therefore mild steel is selected for making this part for assembly.

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10) SPRING

Material Total deformation Equivalent stress/von Mises stress

Cast iron 79.818 1081.1
Mild steel 79.818 1081.1
• Equivalent stress (von Mises stress) and total deformation in analysis for
stainless steel value get equal to cast iron.
• Therefore any material can be used for assembly.

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11) WASHER

Material Total deformation Equivalent stress/von Mises stress

Cast iron 1.4901E-5 1.2426
Mild steel 1.2062E-5 1.2426

• Equivalent stress (von Mises stress) and total deformation in analysis for mild
steel value get equal to cast iron.
• Therefore any material can be used for assembly.

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12) LOCK NUT

Material Total deformation Equivalent stress/von Mises stress

Cast iron 1.401E-5 2.0324
Mild steel 1.2671E-5 1.7284

• Equivalent stress (von Mises stress) and total deformation in analysis for mild
steel value get small as compared with cast iron.
• Therefore mild steel is selected for making this part for assembly.

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13) NUT

Material Total deformation Equivalent stress/von Mises stress

Cast iron 2.4511E-5 2.5429
Mild steel 2.0904E-5 2.0904

• Equivalent stress (von Mises stress) and total deformation in analysis for mild
steel value get small as compared with cast iron.
• Therefore mild steel is selected for making this part for assembly.

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14) ASSEMBLY

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CHAPTER -4
PROJECT INFORMATION
4.1 BILL OF MATERIAL
part no. Name Material for analysis Material selected Quantity
1. Housing Cast iron and mild steel Cast iron * 1
2. Eye link Cast iron and mild steel Mild steel 1
3. Link Cast iron and mild steel Mild steel 2
4. Valve seat Cast iron and mild steel Mild steel 2
5. Valve Cast iron and mild steel Cast iron * 2
6. Pivot Cast iron and mild steel Mild steel 1
7. Pin Cast iron and mild steel Mild steel 3
8. Split pin Cast iron and mild steel Mild steel 3
9. Lever Cast iron and mild steel Mild steel 1
10. Spring Cast iron and mild steel Mild steel 1
11. Washer Cast iron and mild steel Mild steel 1
12. Nut-lock Cast iron and mild steel Mild steel 1
13. Nut Cast iron and mild steel Mild steel 1
(4.1 Bill of material)
4.2 APPLICATIONS

1. Rams bottom safety valve is mostly used in locomotive. It helps to remove

excess amount of steam and heat from the boilers mounted on the
locomotives in old days.
2. In recent days these types of valves are used in industries to make way out
for steams and hot air and heat produces during production in industries.

4.3 OBJECTIVES

1. To remove excess of steam produce in boilers.

2. To remove heat produced in boilers and Make system accident free.

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4.4 MAINTANCE

1) Verify periodically the oiling to the all parts.

2) Maintain the joints perfectly sealed.
3) Oiling to the valve and other parts.
4) Keep all parts clean and dust free, and paint the valve for avoiding from
rusting.

4.5 ADVANTAGES

1. No environment pollution and health hazard occurs from this project.

2. Rams bottom spring loaded safety valve is most economical solution for
removing steams out of boilers.
3. The best thing is that you can choose is spring so that unloading takes place
automatically as the excess of steam and heat removed from boiler.
4. With this machine, the accidents in industries are get reduced.
5. They perform ecofriendly operation and have very long working lifespan.

4.7 DISADVANTAGES

1. This is old technique so that less efficient as compared with recent valve.
2. Due to wet steam is in contact between metal so that rusting will takes place.
3. One operator is required to operate the lever; it’s not fully automatic.

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CHAPTER -5

5.1 CONCLUSION

From this project I get knowledge of how discovery of safety valve takes place, also which
parameters are required in designing the valve are considered. This project also gives information
various types of other valves used in old days.

It gives the importance of safety valve in human life. Human safety is first preference in
industries and that’s why the importance of valve increases. This project covers the all factors related
with rams bottom spring loaded safety valve. With their all parts and their actual design features.
This project also shows the drafting, assembly of project and analysis of project when actual
working takes place on it.

From this project I learnt about how actual designing of any industrial component takes place
by manufacturer. And also get knowledge about analysis of industrial components/parts will takes
place and how the material selection process takes place.

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5.2 REFERENCES

1) “DESIGN OF MACHINE ELEMENTS”- V.B. BHANDARI, THIRD EDITION-DESIGN OF

BEARINGS, DESIGN OF SHAFT, DESIGN OF FRAME.TATA McGraw-HILL, (1994), FIFTH
REPRINT 2011.

2) “MECHANICAL SYSTEM DESIGN”- R.B PATIL, SECOND EDITION- DESIGN OF

FRAME.

3) “MACHINE DESIGN”- N.D BHATT, SECOND EDITION- DESIGN OF SHAFT, SELECTION

OF BEARING, DESIGN OF SHAFT.

4) “INTERNATIONAL JOURNALS ON PRODUCTION RESERCH”- WANG H.S CHAN

AND RFID BASED DIGITAL WAREHOUSE MANAGEMENT IN PAPER INDUSTRY.

5) “SAFETY VALVES AND THEIR FEATURES”- MICHAEL G. KAY DEPARTMENT OF

INDUSTRIAL AND SYSTEM ENGINEERING (2012).

6) “IOSR JOURNALS OF ENGINEERINFG (IOSR JEN) VOLUME 4 ISSUE”- 07 JULLY

2004.

7) “DESIGN OF BUILT IN SAFETY VALVE AND ANLAYSIS”- R. SHARVANAN,

ASSISTANT PORF.BHARAT INSTITUTE OF HIGHER EDUCATION.

8) “SPRING LOALED RAMS BOTTOM SAFETY VALAVE”- WIL COCK D.F AND ER.
BOOSAR M.C GRW.HILL, (1957).

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