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COMPANY PROFILE

LEADER VALVES LIMITED IS A LEADING VALVE MANUFACTURING COMPANY
IN INDIA, TOTALLY INTEGRATED VALVES MANUFACTURING UNIT WITH ITS
OWN FERROUS & NON FERROUS FOUNDRIES, FORGING, MACHINING AND
TESTING FACILITIES.

LEADER VALVES LIMITED IS A LEADING MANUFACTURER OF VALVES AND
BOILER MOUNTINGS IN INDIA PRODUCING MORE THAN 15,00,000 VALVES
ANNUALLY.

HISTORY
LEADER VALVES LIMITED WAS ESTABLISHED IN YEAR 1945 WAS STARTED BY
AN ENTREPRENEUR, NOW LATE MR. P.N.BERI. WITH A WORK FORCE OF JUST
6 TO 7 PEOPLE.

AND AS THE YEARS WENT BY, WITH THE PERSEVERANCE AND DEDICATION
OF THE PEOPLE,THE FLEDGLING COMPANY IS NOW A “COLOSSES” IN THE
VALVE INDUSTRY EMPLOYING OVER 2000 DEDICATED EMPLOYEES WITH
AN ANNUAL TURN OVER OF RS. 600 MILLIONS , NAMED AS
“LEADER VALVES LIMITED”.

AT PRESENT ‘LEADER’ IS BACKED BY A WIDESPREAD NETWORK OF OVER
400 DEALER AND STOCKIEST THROUGHOUT INDIA AND IS ALSO EXPORTING
ITS PRODUCTS WORLDWIDE INCOUNTRIES LIKE EGYPT, SAUDI ARABIA,
SRI LANKA, ENGLAND, SINGAPORE, USA AND GERMANY.

LEADER VALVES HAS ALSO ENTERED INTO AN AGREEMENT WITH
M/S. ENOLGAS. ITALY FOR MARKETING OF THEIR ENTIRE RANGE OF
PRODUCTS IN ALL OVER THE WORLD.

ORGANIZATION CHART

EQUIPPED WITH FOUR INDUCTION FURNACES OF 500 KG. . FOUNDRY FOUNDRIES ARE EQUIPPED WITH EQUIPMENTS ANDLABORATORIES. & 750 KG CAPACITY RESPECTIVELY AND MELT AROUND 500 TONS COPPER ALLOY CASTINGS.

. CASTING BULK OF THE PRODUCTION IS STRESSED UPON SHELL MOLD CASTING PROCESS. OTHER THAN THAT GREEN SAND MOULDING IS ALSO PRACTISED.

A REUSABLE PATTERN ALLOWS FOR HIGHER PRODUCTION RATES. HOWEVER. THE MOLD IS A THIN-WALLED SHELL CREATED FROM APPLYING A SAND-RESIN MIXTURE AROUND A PATTERN. IN THAT MOLTEN METAL IS POURED INTO AN EXPENDABLE MOLD. A METAL PIECE IN THE SHAPE OF THE DESIRED PART. THE PATTERN. SHELL MOLD CASTING PROCESS SHELL MOLD CASTING IS A METAL CASTING PROCESS SIMILAR TO SAND CASTING. IN SHELL MOLD CASTING. . IS REUSED TO FORM MULTIPLE SHELL MOLDS.

ADVANTAGES OF SHELL MOLD CASTING:- CAN FORM COMPLEX SHAPES AND FINE DETAILS VERY GOOD SURFACE FINISH HIGH PRODUCTION RATE LOW LABOR COST SHELL MOLD CASTING ALLOWS THE USE OF BOTH FERROUS AND NON-FERROUS METALS LITTLE SCRAP GENERATED .

. MACHINING WORKSHOP MACHINING IS A TERM USED TO DESCRIBE A VARIETY OF MATERIAL REMOVAL PROCESSES IN WHICH A CUTTING TOOL REMOVES UNWANTED MATERIAL FROM A WORKPIECE TO PRODUCE THE DESIRED SHAPE. WORKSHOPS HAVE MORE THAN 800 MACHINES INCLUDING SPM'S AND CNC MACHINES CAPABLE OF CARRYING OUT ALL TYPES OF PRECISE MACHINING OPERATIONS.

WELDING WELDING IS THE METHOD OF JOINING METALS BY APPLICATION OF HEAT. AT LEADER VALVES LTD. WELDING PROCESSES LIKE ELECTRIC ARC. OTHER THAN WELDING SOLDERING AND BRAZING IS ALSO BEING PRACTISED FOR SOME METALS. GAS WELDING AND TIG WELDING ARE BEING PRACTISED. ELECTRIC ARC GAS WELDING TIG WELDING .

WHY IT IS BEING DONE?:- TO INCREASE HARDNESS OF METALS TO IMPROVE MACHINABILITY TO SOFTEN METALS TO RELIEVE STRESSES SETUP DURING HEATING AND COLD WORKING TO INCREASE QUALITIES OF METAL TO PROVIDE BETTER HEAT RESISTANCE. HEAT TREATMENT HEAT TREATMENT IS PROCESS OF OPERATIONS INVOLVING HEATING AND COOLING OF A METAL IN SOLID STATE FOR PURPOSE OF OBTAINING CERTAIN DESIRABLE PROPERTIES IN METALS WITHOUT CHANGE IN ITS CHEMICAL COMPOSITION.CORROSION AND WEAR PROPERTIES .

TEMPERING. QUENCHING AND NORMALISING ARE BEING PRACTISED.AT LEADER VALVES LTD. BOGEY TYPE FURNANCE IS USED FOR TREATING METALS AND ALLOYS FOR LARGE SIZES. HEAT TREATMENT PROCESSES LIKE ANNEALING. PIT TYPE FURNANCE IS USED FOR TREATING METALS AND ALLOYS FOR SMALL SIZES. .

PROJECT “DESIGN. TO SUGGEST DIFFERENT PARAMETERS THAT CAN BE EMPLOYED IN VALVE BODY DESIGN FOR THE STRENGTHENING OF VALVE BODY SO AS TO DECREASETHE VALUE OF STRESSES. SOLID MODELLING AND STATIC ANALYSIS ON WEDGE GATE VALVE USING SOLID WORKS AND ANSYS.” OBJECTIVE OF PROJECT:- TO FIND THE STRESSES.DEFLECTIONS AND DEFORMATIONS UNDER SAME AMOUNT OF LOADS.STRAINS.STRAINS. .DEFLECTIONS AND DEFORMATION ON THE DIFFERENT ZONES OF VALVE BODY SUBJECTED UNDER STATIC AND HYDRAULIC LOADS.

PLATFORM USED FOR ANALYSIS:. strains. MODULE USED FOR ANALYSIS :.16”-150 WEDGE GATE VALVE is used under simulation for finding stresses. . A valve controls system or process fluid flow and pressure by performing any of the following functions:- Stopping and starting fluid flow Varying (throttling) the amount of fluid flow Controlling the direction of fluid flow METHODOLOGY VALVE BODY USED FOR ANALYSIS:. INTRODUCTION A valve is a mechanical device that controls the flow of fluid and pressure within a system or process.ANSYS 10. deflections and deformation under static and hydraulic loads.0 WORKBENCH. SIMULATION MODULE.

RIBS AND FILLETS were applied on the certain zones of body where the deformation resulted out to be more under simulation of the body. PARAMETERS USED FOR MODIFICATION:. HYDRAULIC LOAD due to pressure exerted by fluid flow.SOLIDWORKS 2008. STATIC LOAD due to force exerted by stem or spindle. MATERIAL OF VALVE BODY :. .PLATFORM USED FOR DESIGNING :. LOADS APPLIED :.CAST STEEL valve body is used for simulation. With the addition of the fillets and ribs to the areas subjected to extreme stresses and deformations were strengthened and due to which after these successful modifications the magnitude of stresses and deformation was actually decreased to certain allowable limit.

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

DESIGN. SOLID MODELLING OF WEDGE GATE VALVE IN SOLID WORKS. .

Isotropic .properties do not change throughout the volume of the part. Homogeneous .0 BODY BEFORE SIMULATION.all properties temperature-independent.STATIC ANALYSIS OF WEDGE GATE VALVE USING ANSYS WORKBENCH 10. MATERIAL DATA The following material behavior assumptions apply to this analysis:- Linear .material properties are identical in all directions. Constant .stress is directly proportional to strain. .

EQUIVALENT STRESS .

MINIMUM PRINCIPAL STRESS .

MAXIMUM PRINCIPAL STRESS .

DEFORMATION .

SAFETY FACTOR .

RESULTS .

. Due to addition of fillets and ribs across the areas subjected to extreme stresses and deformation were strengthened so that they can bear the loads without deformation.PARAMETERS EMPLOYED FOR MODIFICATIONS:- Addition of fillets and ribs across the areas of valve body that is subjected under extreme stresses and deformation.

EQUIVALENT STRESS .

MINIMUM PRINCIPAL STRESS .

SAFETY FACTOR .

RESULTS .

PARAMETERS EMPLOYED FOR MODIFICATIONS:- Addition of fillets and ribs across the areas of valve body that is subjected under extreme stresses and deformation. Due to addition of fillets and ribs across the areas subjected to extreme stresses and deformation were strengthened so that they can bear the loads without deformation. .

EQUIVALENT STRESS .

MINIMUM PRINCIPAL STRESS .

MAXIMUM PRINCIPAL STRESS .

SAFETY FACTOR .

DEFORMATION .

RESULTS AFTER MODIFICATION .

COMPARING WITH THE RESULTS OF VALVE BODY BEFORE MODIFICATION WE CAN CLEARLY FOUND THAT VALUES OF STRESSES AND DEFORMATION HAS DECREASED TO GREAT AMOUNT AFTER CERTAIN MODIFICATIONS IN THE VALVE BODY AND EMPLOYING C. CONCLUSION COMPARING THE RESULTS OF BODY BEFORE MODIFICATION AND BODY AFTER MODIFICATION.A. . BODY BEFORE MODIFICATION BODY AFTER MODIFICATION THEREFORE.E TECHNOLOGY.