Design and Analysis on Feeder System for Hydro Leak in the 10

The shell leak is one of the severe defects which may result in failure of the plant process if it occurs at the installed plant. The shell leak may even cause a fire hazard if the same occurs in the oil and gas plant. There could be a chance of fatal accidents due to shell leak. Hence to avoid these problems the valve bodies are tested with the pressure which is 1.5 times more than the working pressure with a specified time as per the internal guiding standards. These shell leak could be the result of various issues including gas porosity; crack; shrinkage; less wall thickness etc. In order to overcome the above discussed factors, this paper aims with identification of root cause for shrinkage issue, deciding accurate operation to perform by adapting MAGMA software, application of selected/adapted process, and verifying the significances of the selected operation/process. The paper is limited to castings produced by a sand process purely from the inputs received from the past development data of this casting at Foundry(MACPL), analyzing various causes and respective solutions to shrinkage cavity formation, analyzing the effectiveness of proper solution by using MAGMA simulation. With this analysis, a permanent solution is obtained without any further wastage of production time and money.