Erhan Ozkan, International Advanced Researches and Engineering Journal 07(03): 178-184, 2023

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International
Open Access
INTERNATIONAL ADVANCED RESEARCHES
and Volume 07
ENGINEERING JOURNAL Issue 03

e-ISSN: 2618-575X December, 2023

Journal homepage: www.dergipark.org.tr/en/pub/iarej

Research Article

Hydrodynamic behaviour improvement of check valves through CFD analysis

Erhan Ozkan a,*
aDikkan R&D Center, Izmir 35370, Turkey

ARTICLE INFO ABSTRACT

Article history: In this article, the computer assisted design, flow simulation, optimization of production
Received 02 August 2023 parameters and unique design prototype manufacturing of a check valve with 16 bar pressure, 5
Accepted 05 December 2023 m/s flow rate and 52000 m3/h flow coefficients, which have never been achieved before in the
Published 15 December 2023 valve sector, were presented to the attention of the readers. Check valves have a critical role that
Keywords: do not allow reverse flow of the fluid passing through them and are generally designed to secure
CFD the pipeline. A small mistake in design may cause great damage in the system. For this reason, a
FEA new product of which the disc material exposed to 5 m/s fluid velocity, the body subjected to 16
Hydrodynamic bar pressure and the system with a flow coefficient of 52000 m3/h were designed by the
Valve
SolidWorks, the flow was simulated with CFD (Computational Fluid Dynamics), and the
mechanical resistance was analysed by FEA (Finite Element Analysis). Fluent, CFD and
mechanical modules of ANSYS were used to define the parameters of the design. The
manufactures of the products designed in the computer environment have been produced by
casting method with a 45% ferritic microstructure and impact resistance twice as high as the
standard requirements have been implemented.

1. Introduction operating method, installation direction, maximum

pressure, connection point, temperature, closing speed.
Check valves are one-way safety valves that prevent the
The main types are swing check valve, wafer check valve,
fluids passing through the installation from moving in one
spring check valve, tilting check valve, ball check valve,
direction and returning, thus allowing the system to
dual check valve [8-12].
operate more efficiently [1]. Check valves are simple
A check valve requires a minimum pressure between the
devices. They perform a vital function by preventing
inlet and outlet to operate [13-16]. This lowest pressure,
reverse flow. Possible reverse flow in the system can often
which causes the valve to open, is called cracking pressure.
cause damage or malfunction to other equipment
This required minimum pressure varies depending on the
connected to the installation, such as valves and pumps [2].
size and design of the check valve [17]. When choosing a
Even if there is no malfunction, it may cause loss of system
check valve, it should be noted that the system can produce
integrity. The operation of the check valve, which has a
this pressure [18].
single inlet and outlet, is based on pressure difference. The
If the flow pressure in the system drops below the
valve opens when the pressure from the inlet side is greater
separation pressure or a reverse flow occurs, the check
than the pressure from the outlet side. If the pressure in the
valve will close. The closing mechanism inside the check
inlet direction is lower than the pressure in the outlet
valve varies depending on the type [19]. In all cases, the
direction, it closes, and the fluid is prevented from
mechanism inside the check valve will prevent backflow
returning [3]. Check valves do not require a lever, actuator,
and provide sealing [20].
or human power, unlike the opening and closing principle
As the they operate through a single way, it is very
of other valve types. Closing and opening is completely
important to install them in the correct direction to the
automatic [4-7].
installations to be used [21]. If installed in the opposite
There are more than one check valve type depending on
direction, flow will stop and cause pressure build-up. This
the system in which it will be used. The selection should
causes damage to other hardware in the system. There is a
be made according to factors such as type of fluid,
mark on each valves indicating the flow direction [22].

* Corresponding author. Tel.: +90-232-877-17-14; Fax: +90-232-877-17-15.

E-mail addresses: [email protected] (E. Ozkan)
ORCID: 0000-0002-3849-6713
DOI: 10.35860/iarej.1336567 (E. Ozkan)
© 2023, The Author(s). This article is licensed under the CC BY-NC 4.0 International License (https://creativecommons.org/licenses/by-nc/4.0/).
179 Erhan Ozkan, International Advanced Researches and Engineering Journal 07(03): 178-184, 2023

There are some points to consider when choosing a 2. Materials and Methods
check valve. The most important of these criteria are
2.1 Design and Simulation
connection type (flange, threaded, grooved, etc.), highest
pressure and lowest separation pressure, horizontal or CFD is the design and analysis method commonly used in
vertical installation direction, size, material compatibility,
the valve industry. In this way, 3-dimensional flows inside
internal and external temperature, easy access for repair
the valve were simulated using various equations that
[23].
Fluid characterization has a critical role to define the describe the flow conditions. Its importance for designers is
check valve design parameters. CFD (computational fluid that all analyses can be carried out in a virtual environment
dynamics) analysing programs and simulations are often before the prototype is produced. In this way, it will be
used for this purpose. CFD is a branch of fluid mechanics ensured that the product can be transferred to rapid
in which numerical methods and algorithms are used to environmental conditions on the right basis the first time,
analyse and solve fluid mechanics problems. The with less labour and material loss. The three-dimensional
interactions of liquids and gases with solid surfaces are designs of the products were made with the Solidworks
simulated with the help of computers [24,25]. The state of drawing program. ANSYS computer aided simulation
the results relative to the actual interaction depends on the
program was used for CFD analysis and FEA. In CFD
performance of the computer or computers used. When the
analysis, it was solved with the K-epsilon turbulence model,
complex geometries, viscosity, temperature differences
factors are applied to the fundamental equations of and improvements were made in the boundary layers and
classical fluid mechanics, the solution is very difficult, mesh by keeping the y+ value at 3 and below. This model is
even often impossible. In classical fluid mechanics, results the most widely used turbulence model and is mainly used
can only be achieved in idealized simple geometries such for simple turbulent flows. It calculates the relationship
as flat plates and pipes with circular cross-sections. CFD between the kinetic energy of the fluid and the dispersed
is required to obtain results in 99% of the remaining real turbulent kinetic energy.
problems such as lack of fluid, transition from laminar into The strength values of the valve designed in FEA were
the turbulence characteristic, deviation from the steady determined according to the boundary conditions defined in
state condition. For this, the flow region is divided into a the EN 1074 standard. The parts were handled with two
network of small regular elements and points simulating
different numerical methods, singular and assembled, and
the basic differential equations of the flow, and the whole
interpolation solution was realized with the Rayleigh-Ritz
solution is reached step by step from these small elements
with iterations [25-28]. method. It is important to consider the structural damping
In this article, studies on the development of a effects of the system in dynamic analyses. The structural
prototype, which has never been done before, that can damping coefficient, which is generally defined as a constant
operate at high flow loss coefficients provided by disc, coefficient in static analyses, is defined by calculating it
which is a mechanical component used in check valves to separately for the mass and stiffness matrices in dynamic
control the flow speed, dimensions determined by analyses. In order to orient the mass and stiffness matrices
analysing in computer-aided design and simulation correctly, Rayleigh damping coefficients were calculated
environment and at the same time allow double-time and transferred to the system. The boundary conditions
closure with a different piston design were presented in specified in the standard were applied exactly and were
detail. At the same time, details of the challenges defined as one and a half times the nominal pressure value
addressed by the new prototype developed and how it for the body part and ten percent more than the nominal
compares with existing solutions were presented. With the pressure value for the disc part. With the results obtained
prototype developed by CFD and FEA (finite element from this stage, the material analysis and selection stage were
analysis), a product with increased disc strength, started.
optimized valve weight and reduced energy losses by
minimizing resistance to flow is designed. With the 2.2 Material Selection and Justification
intensive use of simulation techniques, the competitive
While modelling the body part in contact with the fluid, a
conditions of environmentally friendly and highly efficient
body material that can withstand one and a half times the
valves have been improved and an innovative product has
body pressure was selected regarding the analyses made
been introduced. The unique aspect of this study is that,
according to EN 12266 and EN 1074 standards. The disc
unlike existing studies in the literature, the production and
material that would withstand ten percent of the pressure
characterization of check valves were presented together
value was selected by the same method, and the material was
using CFD analysis and simulation-supported designs with
chosen regarding to the stresses and deformation results in
different parameters.
the parts according to the body and disc strength analyses.
Considering the FEA results, EN GJS 400-15 (also defined
as GGG 40) material was selected regarding to its high
 Erhan Ozkan, International Advanced Researches and Engineering Journal 07(03): 178-184, 2023 180

strength. The main reason for the high mechanical strength Therefore, the technical details targeted in the article for the
of EN GJS 400-15 material was to obtain a ferritic CFD analyses in line with the requirements defined in the EN
microstructure. The carbon dissolved in the austenite phase 1267 and EN 1074 standards are given in Table 1.
was in the form of spherical graphite dispersed in the ferritic The parameter that would support the velocity vector
microstructure. The samples were produced by sand mould analysis of this system should be its characteristic behaviour
casting method at 1465 °C with 30% dkp steel, 30% ductile under 16 bar pressure, and velocity vector analysis was
iron, and 40% runner ratio. carried out. Accordingly, when the disc was in the fully open
position, the resistance of the disc and the body against flow
2.3 Sample Production and Testing could be characterized more clearly. Innovative design trials
have been carried out to suit the desired conditions. Figure 1
Chemical analysis of the casting material was carried out shows the velocity vector analysis of the system under 5 m/s.
with Metavision 1008 brand spectrometer. The mechanical According to the research in the literature, it has been
properties of the samples were determined by notch impact determined that there are factors that disrupt laminar flows,
and tensile tests. The samples prepared for the notch impact sharp surface change, temperature change and material
test were tested with an OTTO WOLPERT WERKE PW resistance in valve disc materials [29-31]. As a result of these
30/15 brand machine located in the R&D Center at a evaluations, the methodology proved effective in the CFD
temperature of 25 °C, and the samples prepared for the analysis of the disc material at a flow rate of 5 m/s, and it was
tensile test were tested at room temperature with an OTTO observed that the flow lines were suitable in green colour.
WOLPERT U-40 type tensile device. The main reason for
choosing this equipment was that they enable precise Table 1. Technical properties of the design inputs
measurements to be made easily.
Line Pressure (Bar) 16
Fluid Velocity (m/s) 5.0
2.4 Microstructural Analysis
Flow Coefficient (m3/h) 52000
The samples, which were fixed into polyester moulds for
microstructural analysis, were grinded and polished with the
STRUERS Tegrapol-21 brand grinding and polishing device
by turning 90° each time with 600 grades SiC sandpaper, 220
grade 9 μm, 3 μm and 1 μm felt and diamond pastes,
respectively, and made ready for the etching process.
Prepared samples for the microstructure analyses were
etched with 3% Nital solution. The samples were
investigated with a 1000 magnification NIKON ECLIPSE
LV 150 optical microscope. The hardness values were tested
at room temperature with an ALBERT GNEHM brand
universal hardness measuring machine with Brinell tip. It
was possible to conduct more detailed research with these
devices.

2.5 Hydrodynamic Tests

The hydrodynamic tests of the produced body and

mounted disc were carried out according to EN 1074
standard. Regarding to the definition of this standard,
pressure tests were evaluated for the body under 16 bar
pressure without showing the leakage and damage on the
valve. The reason to choose this procedure was to evaluate
the hydrodynamic behaviour of the check valves on the
tough environment.

3. Results and Discussion

One of the most important steps in performing CFD
Figure 1. Velocity vector analyses of the design for front (upper)
analyses properly is to define and handle the data correctly, and isometric (below) views
and more detailed data about the line and fluid is needed.
181 Erhan Ozkan, International Advanced Researches and Engineering Journal 07(03): 178-184, 2023

In order to increase the desired flow coefficient, in other

words, the valve efficiency, various designs have been made
in the disc geometry. The mechanical numerical analysis
method was carried out by defining the boundary condition
of ten percent of the nominal pressure for the disc materials,
which were carried out by considering the yield strength
values of 240 MPa. Accordingly, the mechanical analysis of
the disc regarding to 18 bar, which corresponds to 1.1 times
the maximum working pressure of 16 bar, is shown in Figure
2. The design developed to increase the mechanical strength
of the disc exposed to the flow surface was defined by FEA
and no red areas, which represent high stress zone
encouraging plastic deformation, were observed.
a
The assembly of body, disc, and shaft materials by using
the Solidworks design program and simulations by the help
of ANSYS FEA are shown in Figure 3. In this Figure (a)
represents the body, disc, and shaft assembly. (b) expresses
disc material’s and (c) expresses shaft material’s mechanical
strength by FEA analysis. The most important issue here
would be that no plastic deformation was observed in the
designs. While elastic deformation regions are defined in
green, high plastic deformation is observed in the regions
defined in red. In this case, the material will exhibit
irreversible defects and will dangerously fail in application.
According to the results obtained, the absence of red areas
indicates that there was no plastic deformation in all of the
components, and the results achieved were satisfactory. b
The final version of the solid models of the designs before
casting was realized with the help of Solidworks drawing
program and the final version was decided (Figure 4). The
most important advantage of this stage is to show that 3D
designs of products can be made on a component basis
according to exact measurements. This allows designers to
quickly make final revisions of the product before the
prototype goes into production.

c
Figure 3. Assembled body, disc, and shaft’s FEA analysis

The casting models of the disc and body materials, which

were designed by analysing their hydrodynamic properties,
and the production of the core box were carried out on CNC
machines with CAM software. The wooden models’
productions of the valve components are shown in Figure 5.
The use of CAD-CAM applications gives accurate results
when used for CNC milling. This results in a significant
increase in accuracy. In this sense, it greatly increases control
over the production process. Using CAD-CAM engineering
helps save time at every stage, meaning prototypes and
finished products can be produced much faster. Improved
Figure 2. Mechanical strength definition by FEA
accuracy and time savings also have an important benefit
today: It reduces costs.
 Erhan Ozkan, International Advanced Researches and Engineering Journal 07(03): 178-184, 2023 182

Regarding to the etched microstructure image with

homogeneously distributed graphite with 45% ferrite was
obtained [32,33].
Considering the literature research and standard scans, it
is appropriate that the yield strength of the product is 200
N/mm2 and the tensile strength is 300 N/mm2. As a result of
this study, 250 N/mm2 yield strength and 400 N/mm2 tensile
strength were obtained and ideal conditions were provided.
On the other hand, micro hardness values should be 130-175
HB and Charpy impact test values must be minimum 12
Joule at the room temperature. As the mechanical test results
given in the Table 3, it was observed that the mechanical
values fulfilled the requirements of the standards [34,35].
Figure 4. Final version design made by Solidworks The visual of the prototype production, which has been
casted, assembled, and ready for the hydrodynamic test, is
given in the Figure 7. When the water flow starts, the check
valve flap is pushed by the pushing force of the water and
continues its flow towards the direction of the water flow.
When the water flow stops, the valve starts to close. The
check valve closes with the help of the weight attached to the
flap shaft and the pushing force of the returning water. It
prevents water from returning to the floodplain or flow line.
It has been observed that the design carried out in the solid
model and the prototype production exactly overlap.

Figure 5. Pre-cast preparations of components’ material

The four main factors controlling the microstructure in

cast irons are carbon content, alloying element, solidification
during and after solidification cooling rate and after casting
heat treatments. What makes these stages important are
Figure 6. Casting material etched microstructure image
carbon and phosphorus analyse with manganese and silicon
values. The final chemical of the parts that were the subject Table 2. The mechanical analyses of the disc, body, and shaft
of the study analysis values are shown in Table 2. As can be materials
seen in the chemical composition, ferrite levels of the Yield Tensile
Elongation Hardness Charpy
building elements perlite phase in the structure affects the Strength Strength (HB) (Joule) Structure
(%)
(N/mm2) (N/mm2)
amount of formation. Obtaining a completely pearlitic
250 400 18 150 23 Ferritic
structure, the silicon content must be low, where the
manganese rate has to be high. However, since there was no
need for a full pearlitic structure in this study, cast iron
products containing 2-4% carbon, 0.4-3% silicon, 0.4 - 0.8%
manganese and 0.1 - 0.8% phosphorus were preferred. This
also fulfilled the requirement of the general used cast iron
products.
Microstructure, hardness, shrinkage over the cast part
obtained after the applications of the production processes
strength, % elongation, notch impact tests were performed.
These tests were taken from the cast part itself applied to the
samples. Figure 6 shows the microstructure images.
According to the literature, it was expected to have a high
ferrite content and a homogeneous distribution of sphericity. Figure 7. Prototype production of the developed design
183 Erhan Ozkan, International Advanced Researches and Engineering Journal 07(03): 178-184, 2023

components were showed twice Charpy impact strength

resistance than required and met the tensile-hardness tests
standards requirements.
In final summary, the check valve with %45 ferritic
structure, resistant to the 52000 m3/hour fluid coefficient,
Figure 8. Hydrodynamic test equipment exposed to the flow tests with 5 m/s fluid velocity was
designed successfully. The acceptance tests were carried out
The pressure tests of the produced body and the assembled according to a minimum yield strength of 240 N/mm2 in the
disc were carried out according to defined standard body design, no adverse events were detected under 16 bar
conditions. Materials in contact with water intended for and no plastic deformation occurred in the product under 24
human consumption must comply with the requirements of bar pressure.
national regulations in the country of use and must not affect This research serves as a guide for improving product
the water in any way. This means that the chemistry and geometry through flow analysis. It has been satisfactory that
physical appearance of the water should not change after the needs can be met with the applied mechanical auxiliary
contact with a valve – you should not see, smell, feel or taste equipment. It has increased its R&D capability for similar
any difference in the water. Additionally, all interior and products to be produced. The product that is the subject of
exterior materials must be resistant to corrosion or protected the article is a design, which has the potential for
by appropriate means. Pressure tests were evaluated for the commercialization, as it will increase the manufacturability
body under a pressure of 16 bar without the leakage and of the companies and then the same or similar ones can be
damage on the valve. The design in which the pressure test made within the needs.
was performed is given in the Figure 8.

4. Conclusions Declaration
As a result of the analyses, simulations, prototype The author declared no potential conflicts of interest
production and hydrostatic tests, a unique check valve article with respect to the research, authorship, and/or publication
was presented for the first time in the industry. The project of this article. The author also declared that this article is
has been a guide in improving and developing the product original, was prepared in accordance with international
geometry for the final goal, with various and repetitive publication and research ethics, and ethical committee
applications on flow analysis. At the same time, it has been permission or any special permission is not required.
satisfactory that the needs can be met with the mechanical
auxiliary equipment applied. With this completed project, Author Contributions
R&D capability for the design of variant products has been Erhan Ozkan developed the methodology, performed
increased and national and international patent applications the analysis, and wrote the manuscript.
have been made for the curved body and stepped shaft of the
product that is the output of this project. Regarding this
Acknowledgment
design, R&D Innovation Project has also been successfully
concluded. This study supported by Dikkan Research Program at the
As a result of simulation analyses in products designed for R&D Center approved by Industry and Technology Minister,
use in fluid lines, no turbulent flow was observed at a flow Turkey.
rate of 5 m/s and an ideal laminar flow was determined.
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