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Student, Institution and Industry Track (SIIT)
Student, Institution and Industry Track (SIIT)
Student, Institution and Industry Track (SIIT)
HUBBALLI – 580031.
Semester: I
The successful completion of any task would be in complete without complimenting those
who made it possible by their valuable guidance and encouragement that made my effort
fruitful.
I thank Mr. Mallikarjun Itagi for guiding me throughout my journey by providing valuable
information and encouraging me throughout our internship.
I also thank Dr. M.B. Chavannavar, for their moral support and positive criticism to enhance
my work.
I deeply cherish the splendid efforts and unstinted support of Valtek Corporation Pvt. Ltd.
Dharwad workers who helped to make this internship into its real existence.
INDEX
The researcher wanted to apply the knowledge he has acquired to the industry
workplace.
The researcher wants to know the practical knowledge about the management process
of the company.
OBJECTIVE
METHODOLOGY
The researcher has collected primary & secondary data about the organization from the
company. In these report researcher has studied about the structure of the organization,
various departments & their functions. The researcher has also studied about the product and
machines that are used in the company.
INTRODUCTION
This is an opportunity given by the college to the 8th semester students who want to have an
exposure of the industry. It provides a good platform for the students to have an industrial
professional background before actually getting to work in an industry after the graduation.
The importance of industrial training to student an internship will be a structured work
experience related to a student's major. This is an experience that will enhance the students’
academic career and personal development.
This internship will be supervised by a professional in the field which will be great learning
experience as an individual. It will be great experience for a college student to work in a team
which will be delivering solutions to the real-world business. Can learn new skills and add to
our knowledge base while gaining confidence in our abilities.
All departments like planning, production, purchase, store. Quality, control and accounting
departments have coordination in a smoother way so the result is company running in a
profitable way.
COMPANY PROFILE
Email Id valtekdwd@yahoo.com
Fax 0836-02460149
No. 4, RT Nagar,
Matadahalli Extension,
Bengaluru- 560032
Facility for testing Hydraulically mounted test beds to carry out testing
activities
VISION/MISSION AND QUALITY POLICY:
VISION:
MISSION:
Mission is to manufacture quality valve products for the industry worldwide. We embrace
the concept of total quality and people involvement to enhance “TOTAL CUSTOMER
SATISFACTION” and commit to maintain this standard of excellent through continual
improvement and use of quality management systems
QUALITY POLICY:
INTERNAL ENVIRONMENT
PURCHASE DEPARTMENT:
The purchasing department receives a list of a raw materials and services required by the
production department to complete the customers’ orders. The purchasing departments
send purchase order to select to deliver the selected raw materials to the manufacturing
site on the required date.
First they prepare a list of materials according to the requirement and send to the purchase
section. First it goes to the section weather they are having a required stock then the purchase
office invite quotation from different companies by sending enquiry letter after receiving the
quotation according to their price and quantity. Then they discuss about the purchase. Officer
sends the purchase order to the concerned company suppliers their required materials within
mentioned dates.
PURCHASING PROCESS
Ensure exercise of control on supplier and extent of such department on the criticality of
product and effect of purchased product on subsequent product realization/final products.
It ensures evaluation and selection of suppliers based on their ability to supply product
on per organization requirements.
HR DEPARTMENT:
HR is competence on the basis of education, training, skill and experience is ensured in every
position whose performing work effects conformity to product quality this covers statutory
and regulatory requirements.
HR TRAINING ENSURES:
Determining competence level of personnel performing work effecting product
quality specification through gap analysis.
Wherever applicable organization has determined on the job to ensure that gap is
minimized. If required organize training.
Ensure that is personnel are aware of the relevance and importance of their activities
and now they contribute to the achievement of the qualities objects.
Evaluating the effectiveness of training provided takes other activities to achieve the
necessary competence.
Maintaining appropriate training records are also records of education, skills and
experience.
FUNCTIONS OF HR DEPARTMENT:
To receive employees.
To look over welfare activities of workers.
Make provident funds.
Salaries bonus must be given to employees.
Process Flow:
Order Booking:
Customers like L&T valves place their order to BDK Engineering Industries Limited.
BDK Engineering Industries Limited will send the order copy along with Bill of
Materials and Engineering drawings based on customer requirements.
Valtek Corporation takes the order and sends the copies to planning department.
Planning:
The planning department will create a production plan to produce the valves to fulfil
customers’ orders. To manufacture valves the company will then have to purchase the
raw materials needed.
Placing orders for raw materials and some parts for valve assembly.
Sending casting drawings and other details to casting industry.
Inspecting the inventory for proper utilization.
Setting the deadline for each process.
Machining:
Quality and Control dept. will inspect the casting parts and other raw materials. If any
defects found, those parts will be rejected and sent back to suppliers. Else parts will
be sent to production department.
Production Department inspects the dimensions of valve parts and compare with
machining drawings for further operations to carry out.
Operations:
In order to match the Outer Diameter (OD), Internal Diameter (ID) of any valve body
turning operation is carried out in VTL.
In order to match length of valve body facing operation is carried out in VTL.
If size of valve body is too large and requires more precision work then these
operations are carried out in CNC VTL.
For drilling holes on the flange and other parts Drilling operation is carried out on
Radial Drilling Machine.
To have internal threads inside whole Tapping is carried out on Radial Drilling
Machine. In case of Butterfly valves Hand tapping is also used to have internal
threads inside small holes.
For Super Finishing of valve body Lapping operation is carried out. For some of the
expensive valves super finishing is carried out by Shot Blasting.
Production Department:
Abbreviations:
WO --Work order
QAP -- Quality activity plan.
API -- American petroleum institute
QA-Quality assurance
GAD -- General assembly drawing
BOM – Bill Of Materials
Responsibility:
It is the responsibility of the shift supervisor to issue the shift supervisor to issue the process
control sheet duly filled which is included under document number and relevant drawing to
the operators. He is also responsible to ensure that components machined by operator are as
per drawing.
Shift supervisor instruct to the operator for machining of body along with drawing,
material and process control sheet.
Operator should go through the drawing and collect suitable calibrated instruments for
checking the dimensions.
Load the component on the machine using crane or manually.
Clamp the component in fully tightened condition and ensure the trueness of the
component.
Collect the suitable tools/inserts required for machining the components.
Start the machine and ensure the coolant is ON.
Before the final cut visual inspection to be done for material defects, in case of defects
inform supervisor for further course of action. In case of no defects continue final
machining. After completion check the final dimensions as per drawing.
After achieving the required dimensions clean the component and unload the
component from the machine carefully with the help of crane or manually.
Offer QA person for inspection, once cleared by QA components are sent to further
process.
Responsibility:
Assembly in charge is responsible to provide the assembly job card, instructions and
material to the fitter.
It is the responsibility of the fitter to carry out the assembly as per given instructions
and complete the necessary records.
It is the responsibility of assembly in-charge to prepare the process control chuirt and
after assembly quality. Inspector is responsible to verify and sign the process control
chart.
It is responsibility of assembly in charge to hem numbers/identification numbers
collected from components with ERP. Before entering same in assembly job card.
Instructions:
Collect duly machined and inspected component and internal parts from stores
through material requisition.
Check all the parts for sharp edges and scratch lines, dent, damages, etc.
Remove all sharp corners and clean all components. For stainless steel components
before assembly water wash has to be done for body, insert dry the components by air
with suitable method. Refer process control work instruction document.
For carbon steel components body and ends clean with using thinner and apply rust
preventive on all machined parts except seat a scale areas and ball to be washed and
dried.
Apply the suitable threading paste in threaded area.
Tighten the check nut as per torque chart by using suitable torque wrench Operate the
valve thrice and ensure free operation with specified arm. Mention the work order
serial number on ends party side flange face.
For lever operated valve follow the work instruction for mounting accessories for gear
operated valve follow the work instruction for mounting accessories.
Keep valve in open condition.
Fix the end caps on both sides.
Enter the heat number in job card.
After completion of all the activity handover the assembly valve to testing section.
Assembly methods:
After machining of individual parts of a particular valve, the assembly process takes
place.
Arc welding is more commonly used process for joining of the parts at Valtek.
Since the parts are heavy and therefore require machine’s help. Cranes are used for
the movement of the parts and assembled at one place.
After the complete assembly of the valve, it is sent to the testing facility for checking
of safety of the valve.
Inspection Methods:
The assembled valves are measured with measuring tools such as vernier calliper,
micro meter, shell thickness measuring instrument.
Once it is clear with respect to the dimension of the valves, then valves are brought to
test facility for testing pressure limitation.
The valves are tested at the testing facility for backseat leakage, pressure limit etc.
Each valve has its own pressure limit and allowed leakage limit depending on the
customer requirement.
Two different types of tests are being conducted at this facility one is with water
pressure and another one with gas pressure.
WORK FLOW MODEL:
TECHNICAL CONTENTS
Products
Swing Check Valve is designed to prevent the reversal of flow in a piping system.
These valves are activated by the flowing material in the pipeline.
The pressure of the fluid passing through the system opens the valve, while any
reversal of flow will close the valve.
Closure is accomplished by the weight of the check mechanism, by back pressure, by
a spring, or by a combination of these means. The general types of check valves are
swing, tilting-disk, piston, butterfly, and stop.
A swing check valve allows full, unobstructed flow and automatically closes as
pressure decreases.
These valves are fully closed when the flow reaches zero and prevent back flow.
Turbulence and pressure drop within the valve are very low.
A swing check valve is normally recommended for use in systems employing gate
valves because of the low pressure drop across the valve. Swing check valves are
available in either Y-pattern or straight body design.
Applications:
Check valves are used in various industries like Offshore Oil & Gas Production,
Onshore Oil & Gas Production, Gas Plant, LNG, Liquid Gases, Refinery,
Petrochemical, Chemical, Fertilizer, Terminals, Pipeline, Power, Desalination, Water,
etc.
Advantages:
Prevents backflow
Maintains pressure
Serves as backup system
Most can be used horizontally as well as vertically
Disadvantages:
Since all moving parts are enclosed, it is difficult to determine whether the valve is
open or closed. Furthermore, the condition of internal parts cannot be assessed.
Each type of check valve has limitations on its installation configurations.
Valve disc can stick in open position.
B. Butterfly Valve
Fig 2. Parts of Butterfly Valve
Applications:
A Butterfly valve can be used in many different fluid services and they perform well
in slurry applications. The following are some typical applications of Butterfly valves:
Cooling water, air, gases, fire protection etc.
Slurry and similar services
High-pressure and high-temperature water and steam services.
Advantages:
Disadvantages:
Centre or Engine Lathe Machine is the most widely used lathe machine and still, it is, in
every workshop, this machine is present.
At Valtek, this machine is used only for the machining of butterfly valves.
This machine is used for operation like Turning, facing, grooving, drilling, knurling, facing,
boring etc. after the casting of valves to get the required dimension.
Initially rough turning was performed to remove the excess material according to the
manufacturing drawing of the valves.
Then the smooth turning is performed to achieve the dimension according to the
manufacturing drawings.
At Valtek, this machine is used to machine those valves which require high dimensional
accuracy, relatively good surface finish.
Generally these types of valves are required for chemical industries, Gas plants where even a
small leakage can cause a heavy damage. This machine is basically a CNC VTL.
3. Shot Blasting
Fig 5. Shot Blasting Step by Step Operation
Shot is loaded in the hopper of the machine. The hopper acts as a funnel to direct the shot to
the shot valve, which is also referred to as the butterfly valve.
The shot valve controls the amount of shot that is allowed to flow down a spout and into the
blast housing. The shot valve is control by cable or lever located in the operator’s position for
easy accessibility.
After passing through the shot valve the flow of shot is directed by a ‘Control Cage’. This
ensures the shot will fall in the right spot of the blast wheel. The Control Cage can be
adjusted to guarantee that the Shot Blaster is achieving an even blast pattern across the width
of the machine.
After passing through the Control Cage, the shot is impacted by the Blast Wheel and flung at
a very high speed towards the floor. Depending on the size of the machine, the blast wheel
can either be a one-piece unit or made up of centre housing with a series of blades, which are
also referred to as paddles.
The abrasive shot hits the floor with such great force so that it is able to remove surface
coatings and other contaminants, leaving the concrete clean, dry and ready to be finished, if
necessary.
4. Radial Drilling Machine:
A radial drilling machine or radial arm press is a geared drill head that is mounted on an arm
assembly that can be moved around to the extent of its arm reach. The most important
components are the arm, column, and the drill head. The drill head of the radial drilling
machine can be moved, adjusted in height, and rotated. Aside from its compact design, the
radial drill press is capable of positioning its drill head to the work piece through this radial
arm mechanism.
This is probably one of the reasons why more machinists prefer using this type of drilling
machine. In fact, the radial drilling machine is considered the most versatile type of drill
press. The tasks that a radial drilling machine can do include boring holes, countersinking,
and grinding off small particles in masonry works.
Colour Code for Materials:
Since metals can be classified into many different grades of material under each individual
metallic group, identifying them with names may not be feasible; therefore they are marked
with specific indications to which each of them may comply.
Generally these markings are done through metal dies, but for metals which are intolerable to
die stamping and prone to getting damaged, methods like stencilling or enamel printing is
considered safer.
Findings
In any production industry safety and health of the workers need to be handled with
utmost care. So in Valtek all the safety measures are taken while working in shop
floor. And workers are provided with allowances like Delay Allowance, Fatigue
allowance, Personal allowance etc. which adds to the total productivity and also
eliminates the possible human errors.
Pull production strategy is used i.e. valves are manufactured only when orders are
received which helps in reducing waste, low inventory.
Proper sequence of operation is followed at each stage of production.
All the documents viz. BOM, Casting and Machining drawings, Inspections reports,
testing reports are maintained in standard formats.
Machining instructions were followed at regular intervals which increased the
machining rate and also life of the cutting tools. Systematic flow of components from
one machine to another machine for undergoing different operations which resulted in
decreasing the machining time.
Guidelines related to preventive maintenance for machines were strictly followed
which resulted in avoiding the brake-down of machines. All the machines were
inspected and lubricated at regular intervals. And all measuring equipments were
calibrated at regular intervals.
In order to meet some special requirements of customers, the required facilities and
equipments like CNC, Shot blasting were setup in industry.
Instructions related to specific type of valve assembly were followed which resulted
in exact assembly of valve.
Recommendations:
Industries seek to reduce time of production, waste and enhance revenue. Kaizen and
Kanban systems are best live examples for this scenario. So I recommend
implementing and practicing Kaizen and Kanban systems which not only increases
productivity but also provides safe working environment and improves employer-
employee relation.
Industries should try to adapt to newer technology and trends in business in order to
stay in competition. So implementing the automation in the assembly line will reduce
the assembly time which results in increase of productivity.
Implementing the checklist chart or digital board in assembly line will reduce the
missing of components during assembly.
Final products, semi finished products, or part supplies kept in inventory do not add
any value. Reduce the unnecessary usage of inventory. And inventory can be used for
adding new machines or facility that may increases the productivity.
CONCLUSION
Initially I was unaware about the general industry terms and security policies. Client’s data
privacy and commitments are strictly followed in the companies. This program emphasized
me to deeply think about real world live industrial problems.
Understood the importance of Just in time (JIT) production i.e. pull production system in
industries like Valtek.
Manufacturing department in Valtek enabled me to learn about the different types of valves
and their applications in industries. It also helped me to understand the industry drawings,
tolerances etc, and identify materials based on colour codes.
http://valtekcorporation.net/about.html
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application-butterfly-valves
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used/
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gate- valve
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