The SMART DESIGN of a new generation of knife gate valves.

Sewage systems are certainly not a new development. Already in roman days complex designs of drainage systems such as the Cloaca Maxima where introduced. What have changed are the engineering tools to design very cost effective solutions for valves, penstocks (sluice or gate).

Industrial Penstocks Ltd approached Simpact as design consultants to assist in the design of a new large diameter Knife Gate Valve for the sewage industry. Four load cases were identified for analysis to ensure the valve design provides a robust solution to warrant trouble free operation over its life span.

Through the use of our CAE design tools, we were able to tune the gauge of the components in a parametric 2D shell model. With this FEA model, global stress distribution over the finite elements could be assessed. It also allowed selecting the right mix of material qualities for a sound design. The stiffness and strength of the valve design was inspected, and gauges were optimised to meet the prescribed criteria. With the derived thicknesses and simple, yet effective design modifications, a new computer aided design, CAD model was created of the valves by the team at Industrial Penstocks.

The updated CAD was used to produce a detailed, 3D validation FE model to which the same load cases were applied. The solid mesh of finite elements allowed detailed assessment of local stresses. During spring 2009, Simpact commissioned a new powerful multi processor 64-bit solver platform which enabled a quick turnaround of these by nature very large computer models. From the results of these analyses, final concept refinements were implemented into the design to aid the operation and longevity of the valves. Once again, Industrial Penstocks Ltd. has put a leading product in the market.