Techno Economic Review on Casting Design Steam Turbine Emergency Stop Valve (ESV) Housing

Abstract

The development of computer aided design (CAE) technology, especially casting simulation software (Magmasoft v5), can be utilized maximally as a tool to verify the design of castings that have been made to be able to meet the elements of QCD (quality, cost, delivery) and compete in the market. This study aims to obtain an optimal ESV housing casting design by reviewing and modifying the casting design in terms of both quality and economics. The process of design optimization with casting simulation is an important step in the design and development of casting products to improve casting yield and casting quality. The optimal design of castings is obtained by improving the design through pouring system using bottom pouring and optimizing the riser design. The results of this study obtained Design # 2 as a design choice of pouring system because it can improve the quality of casting products. Design # 2 optimized again into Design # 4 as the optimum design and able to increase the yield casting by 5.11% from the previous design (Design # 2). The result of techno economic analysis shows that by allocating 4% budget for design cost can contribute to decrease of production cost of foundry ESV housing up to 54,95%.