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We are committed to continuous development and strive to formulate ideas that will maintain industrial Penstocks as a leading light in our industry. We will do this by listening to our customers and keeping pace with technical innovation.

industrial Penstocks was one of the first companies to manufacture a penstock that could withstand 18m of pressure.

Finite Element Analysis

industrial Penstocks Ltd approached Simpact 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 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, new CAD 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.

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.

Photo elastic stress analysis

From partnering with a University we have been able to bring an innovative solution to the market, delivering a major unique selling point.

This innovation has provided a new automated photo elastic analysis technique which has demonstrated its effectiveness in very quickly determining the optimum load path to achieve the required fatigue test.

Although an academic exercise being utilised to validate a fatigue prediction software, it could obviously be used to validate similar test parameters on real components

Tests were carried out by firstly brushing a thin coating on a specimen cross member. Then using a unique Stress Photonics automated polariscope, stress distribution levels could be evaluated during assembly of the specimen during loading. The system not only takes stress images after incremental loading but, is also capable of recording a “stress movie” whilst the fatigue test was running.

The technique was used to reduce assembly stresses to a minimum and to ensure that sufficient stress concentration was present in the notch area

The new automated analysis technique has demonstrated its effectiveness in very quickly determining the optimum load path to achieve the required fatigue test.

Although this was an academic exercise to validate some fatigue prediction software it could obviously be used to validate similar test parameters on real components.

The fact that the FEA wrongly predicted the original load path, hence stress distribution, shows that this type of experimental validation is still invaluable within a real product development program.

 

Physical product testing

To support our proactive development program industrial PENSTOCKS, has developed its own in house testing facility.

We are able to test for both on seating and off seating conditions.

Our in house valve test facility is capable of testing and operating valves up to 2000mm dia and for pressures up to 24 bar.

As a part of our continued development program, industrial Penstocks can test valves up to 2000mm dia