Product Development

Presented by
Nakul Kuri, Mechanical Engineer(CFD & FEA)
Working as AGM-R&D,
McNally Sayaji Engineering Limited, Kolkata, India
I am a graduate mechanical engineer having more than 20 years of experience in new product
development as per International Standards and have developed various type of equipment -
Pumps, Pelton Turbine, Pressure vessel and Thickeners etc. I have working experience in both
domestic and global environment of companies like ALSTOM-France, Pentair-USA and CADtech
Consultants-India, DE’s Technico-India.

Presently I am working as an Assistant General Manager at R&D department of McNally Sayaji

Engineering Limited (MSEL), a subsidiary of McNally Bharat Engineering Company Limited
(MBE), Kolkata, India

In MSEL, I am leading the pump design team and responsible for development of Slurry Pumps
using CFD simulation software and also responsible for design optimization of Thickeners and
Wagon Tippler including both strength calculation and FEA in ANSYS. I am also involved in root
cause failure analysis of rotating as well as static equipment.
 Bachelor Of Mechanical Engineering From Jorhat Engineering College,
Dibrugarh University, Govt. of Assam in Oct.1997

 Certified in ANSYS CFX and also ANSYS-Mechanical from ANSYS India

 Certified SolidWorks Professional (CSWP) from SolidWorks Inc.,USA

 Certified in Pro-E Wildfire3.0 (3D Model and drafting)

 Trained in KYPIPE from Pentair Water, Ohio, USA

 Trained in Pelton Turbine design from ALSTOM R &D, Grenoble, France

 Trained in GD&T as per ASME Standard Y14.5M-1994. & Pump Assembly

Stack-up analysis.
Summary …

 New Pump Hydraulic Design as per HI standards and CFD simulation of pump or
Improvement of its efficiency.

 Development of Bolted design tank with skid mounted thickener.

 Design optimization to minimize the weight of existing product Wagon Tippler, Pump etc.

 3D model of parts, assembly and detailed design in PRO-E/CREO 2.0 and SolidWorks.

 Performing FEA simulation with ANSYS Workbench (Vibration frequency Analysis, Static
and dynamic Analysis) for various equipment like Pump, Turbine, Vessels, Thickeners and
Wagon Tippler etc.

 Design improvement and trouble shoot analysis of existing product

 Pressure Vessel Design and mechanical strength calculation as per ASME Section VIII-DIV-1

 Checking and approve detailed manufacturing drawing with GD&T and co-ordinate with
manufacturing team and design team

 Design documentation and making technical report of product Development.

 Developed new series of slurry pump installed various process plant like
Bhilai Steel Plant, Jindal Steel and Power Plant etc.

 Developed new Submersible sump pumps which are successfully installed

at various part of North America.

 Designed and developed a new Pelton turbine with high efficiency and
model test done successfully in Global Technology Centre, ALSTOM-India.

 Designed and developed pressure vessels / storage tank and successfully

installed at various IOCL Refineries and also at Haldia Petrochemical
Limited.

 Paper Published on Flow Analysis of a Centrifugal Slurry Pump in The 11th

Asian International Conference on Fluid Machinery and paper ID:
AICFM_TM_003

 Invited speaker for customer talk at ANSYS Seminar on Simulation of

product development
SIDE MOUNTING REVERSE MOUNTING
PRELIMINARY HYDRAULIC COMPUTATIONAL FLUID SOLID PARTICLE MOTION
DESIGN AND 3D MODEL DYNAMICS(CFD) SIMULATION ANALYSIS WITH CFD
OF PUMP HYDRAULIC MODEL SIMULATION

3D CAD MODEL AND FEA FINAL CAD MODEL FOR DESIGN VALIDATION TEST
ANALYSIS PROTOTYPE MANUFACTURING CONDUCT IN OUR IN-HOUSE TEST
RIG IN MALUR, KARNATAKA
OBJECTIVE:
 To develop new bolted thickener tank with skid mounted support to add a new series of product in-line
with existing welded design thickeners.
 Application mainly on sand beneficiation plant.

DESIGN MODEL ACTUAL PROTOTYPE MODEL

FEA- RESULTS
OBJECTIVE:
 Main objective of this project is to optimize the weight of a present wagon tippler such that the overall
cost of the machine can be optimized and at the same time the efficiency of the machine can be improved.
 For the said purpose a general Finite Element Analysis software ANSYS structural has been deployed for
structural analysis along with CREO Parametric for 3D model generation

The main components of wagon tippler are

as follows:
I. Cradle/ Tippler platform
II. End rings
III. Side support beam
IV. Top clamp assembly
V. Drive unit
FEA- RESULTS
ANALYSIS REPORT
THANK YOU