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Prem Fouress Report
Prem Fouress Report
KNOWLEDGE IS POWER
INTERNSHIP REPORT ON
In fulfilment
of the internship
about the Butterfly
valve
CERTIFICATE
This is to certify that the internship in FOURESS ENGINEERING INDIA
PVT LIMITED is carried out by PREM KUMAR.R (R19ME093) a
bonafide student at Reva University, towards the partial fulfilment for the
award Bachelor of Technology in Mechanical Engineering during the year
2022-2023. It is certified that all corrections/suggestions indicated for
continuous internal assessment have been incorporated in the report to the best
of our knowledge. This report has been approved as it satisfies the
requirements in respect of Internship.
ACKNOWLEDGEMENT
Interning at FOURESS INDIA PVT LTD. was a great learning experience and helped me grow, both as
a professional and as an individual.
I thank FOURESS INDIA PVT LTD. for accepting me as an intern and the HR Mr. Y SHANKAR
MURTHY for making the internship application process so smooth. I express my heartfelt gratitude to
the Managing Director of FOURESS INDIA PVT LTD., for constantly mentoring and guiding me for
the entire duration of my internship. I thank them for providing me with their precious time and for
clearing all my doubts. I would also like to take this opportunity to thank everyone at FOURESS INDIA
PVT LTD., Bangalore for providing me with a prospect to intern along with helping me and clearing all
my doubts.
Last but not the least; I would like to thank my parents for being my pillar of support throughout this
internship and even beyond.
I also extend my gratitude and regards to everyone who has helped me directly or indirectly throughout
the internship.
PREM KUMAR. R
EXECUTIVE SUMMARY
This report summarizes my experience and learning as an intern at the Production Engineering
Department of FOURESS ENGINEERING INDIA PRIVATE LTD. from 26-07-2022 until 16-08-
2022. My internship mainly focused on the BUTTERFLY VALVES.
After thoroughly understanding the manufacturing process of valves, seat ring by observing the different
processes and machines, I focused mainly on the Inventory Atomization, spending most of my time
observing and talking to operators at the production unit responsible for the same and in the report, I've
tried to summarize the same.
The report contains all major observations and conclusions regarding my work as an intern. It also
contains various software and charts for easy understanding. The report aims at highlighting the process
of Inventory Atomization and different suggestions that could prove to be useful to reduce the time of
inventory.
The report also summarizes the knowledge I have gained as an intern and the various practical aspects of
everything I had learnt so far in theory classes. I had the opportunity to see the practical application of
different topics I have learnt so far in my course beginning from the semester till the now. I am sure this
experience is also going to help me going further in my studies.
TABLE OF CONTENT:
• ACKNOWLEDGEMENT.......................................................................................... 3
• EXECUTIVE SUMMARY.........................................................................................4
• COMPANY PROFILE............................................................................................... 6
• CHAPTER - 1
• INTERNSHIP OUTCOMES
COMPANY PROFILE
From its inception over five decades ago, FOURESS was laid on a foundation of enterprise, integrity,
innovation. The Focus was to use core engineering strengths, to make valves in India on par with
imported products used in the Power and Water industries.
The FOURESS Group of companies is a premier global supplier for engineered products in industrial
flow related applications manufactured in India, to reach every industry in all parts of the world, on the
strength of its quality, competitiveness, and ability to meet the need-based delivery.
Our track record, built over decades of success, our customer-focused Design and R&D, our
manufacturing capabilities, competitive labour, and the spirit of reaching out to the opportunities have all
provided the right blend for growth and excellence.
FOURESS ENGINEERING (INDIA) PVT LTD is the flagship company of the FOURESS GROUP of
companies, and the leading supplier of Flow Control Devices for Power, Water, Wastewater, Steel, Oil &
Gas, Refinery & Petrochemical sectors in India. We commenced operations in 1962 with the manufacture
of carbon steel industrial valves at Thane, and in 1973 signed what was to be the first of many Foreign
Collaboration Agreements with world renowned Valve Manufacturers in the U.K, Germany, Switzerland,
and Japan.
Growing markets, shifts in production and the demand for a vast range of products and the latest
technology has further led to the setting up of 8 factories in India, including at Bangalore, Aurangabad,
Chennai, and Baroda. FOURESS specializes in custom-engineered Valves and Gas Tight Isolators
(Dampers), knife gate valve for power, water, steam, oil, and gas applications and has supplied reliable
and durable products to the projects in over 50 countries in 6 continents.
FOURESS ENGINEERING (INDIA) PVT LTD has emerged as a leading player in the
global market for industrial valves, isolators, high intensity dampers and gas line valves
COMPANY OVERVIEW
• Company's authorized capital stands at Rs 1000.0 lakhs and has 75.0% paid-up capital which is Rs
750.0 lakhs. Fouress Engineering (India) limited last annual general meet (AGM) happened on 30
Sep, 2020. The company last updated its financials on 31 Mar, 2021as per Ministry of Corporate
Affairs (MCA).
• Production activities supported by work force of over 1000 and modern equipment’s.
• A valve is a device or natural object that regulates, directs or controls the flow of a fluid (gases,
liquids, fluidized solids, or slurries) by opening, closing, or partially obstructing various passageways.
• The use of valves to regulate the flow of water dates to Indus valley (1700 to 1800 BC).
• Major valve design began during era of industrial revolution and with use and development of steam
(1700 AD).
• Modern butterfly valve was first invented by Mr. Carl Benz in 1983 to regulate the flow of carburettor.
• Early 1920’s the emergence of hydropower technology and many companies developed the valves,
conducted model tests.1950 onwards. Butterfly valves were extensively used in Hydropower plant.
Bangalore plant is into design and manufacturing of isolation valve like the following:
• Butterfly valves
• Triple eccentric spherical valves
• Knife gate valve
• Isolators
• Dampers.
.
The butterfly valves are used in thermal power plants, Water treatment plants, process industry and
hydro power plants.
Most cases these valves are used for isolation purposes however, butterfly valves are also used for
control/throttling duty.
Valves
GALLERY
1. 2.
3. 4.
1. 3100mm Hydraulically operated penstock protection valve to Wyangala hydroelectric Power Station,
Australia.
2. 3600mm electrically operated knife gate valve with super duplex ss blade and lining to Stone Cutter
Island, Hong Kong.
3. 17500mm x 4012mm electro-hydraulically operated multi louvre damper to Taiwan through Mitsui
Babcock, UK
4. 1400MM Electrically operated butterfly valve supplied to NKK, Japan.
Production Units:
There are 5 Production Units (PUs) in Fouress Engineering Pvt Ltd., Bangalore plant for manufacturing a
range of butterfly valves, high performance valves. Most of these production units are a customer or
supplier to another production unit in the same plant.
• In this unit, Designers are the key part of a design team. They are a group of design experts that create,
test, and iterate product design drafts again and again to ensure better product and user experiences.
• Crio and Solid works are the main design tools used to Build professional Projects.
• Design team is being induced right from DE state, where the informed requirements are understood &
clarified at each step & quoted accordingly to bag the order.
• Design team generate design output from the design input.
• Verification of design and ensure design output meets input requirements.
• Review of design documents drawings, specification sheet calculation for correctness, completeness,
and release for further processing.
• Initiate design changes based on feedback received.
• Checking of design documents and drawings, bill materials.
• Revisions in drawings/documents.
• Approval of part drawings as per instructions.
• Design team should check for calculations.
Depending on the design submitted by the design team. As soon as the job pocket is prepared, it is
sent to the manufacturing supervisor, who then assigns the task to the operators to complete.
The main production of the machine shop are the parts for the valves
• Body
• Disc
• Steam and seat
• Drive shaft
• Stub shaft
• End cover plate
• Thrust pad
A manufacturing company, Fouress engineering purchases raw materials and then processes them on
the machines available. Each part of the butterfly valve is made from scratch.
Manufacturing machinery:
B. TECH MECHANICAL ENGG 13
FOURESS ENGINEERING India. PVT Ltd 2022
Boring
Cutting
Drilling
Facing
Internal forming
Knurling
Necking
After the valve is manufactured and fabricated, it is ready for insertion into the next process.
Fouress's core manufacturing process required bringing in gear boxes and actuators from OEM
vendors.
In this case, the main suppliers are AUMA PVT LTD, they provide the gearbox and the actuators for
the valves
Based on customer requirements, gear box is manufactured
Lever operated, gear operated, electrically operated, and pneumatically operated.
The operators are mainly produced from AUMA/ ROTANK manufacturing.
QUALITY
CONTROL
Quality control involves testing butterfly valves and determining if they are within the specifications
and Requirements for the final product. The purpose of the testing is to determine any needs for
corrective actions in the manufacturing process. Good quality control helps companies meet
consumer demands for better products.
Carry out quality assessment measures of all the products ready to be shipped and incoming raw
materials
Take a thorough look at the plans, specifications, and blueprints to understand the product
requirements
Reject all the incoming raw materials fail to meet quality expectations and report the issue to the
concerned department at the earliest
Case study-01
Welding
B. TECH MECHANICAL ENGG 18
FOURESS ENGINEERING India. PVT Ltd 2022
Types of welding:
2. Tungsten Inert Gas(TIG) welding:Tig welding is an arc welding process that uses a non-
consumable tungsten electrode to produce the weld. The weld area and electrode are
protected from oxidation or other atmospheric contamination by an inert shielding
gas(argon or helium). A filler metal is normally used, though some welds, known
as autogenous welds, or fusion welds do not require it. When helium is used, this is
known as heliarc welding
Industries use TIG welding on the thin workpiece, especially nonferrous metals
3. Metal Inert Gas (MIG) welding:Mig welding is an arc welding process that uses a
continuous solid wire electrode heated and fed into the weld pool from a welding gun. The
two base materials are melted together forming a join. The gun feeds a shielding gas
alongside the electrode helping protect the weld pool from airborne contaminants.
Welding joints:
INTERNSHIP OUTCOMES
• From the month-long experience interning at Fouress engineering, we were able to learn a lot about
the working of the company in terms of how the nine production units are linked in their production
activities with one unit acting as an internal customer for another in addition to manufacturing
components for dispatch to external customers.
• We observed the manufacture of products including disc\, bodies, shaft, etc. which were
customized solutions to problems that customers needed to resolve.
• The designs for these solutions were prepared in the Research & Development department who sent
the specifications through a drawing sheet to the concerned Production Unit for manufacture.
• We learnt the packing procedure of products in PU 1 (Shop floor)
• We also noted down different values such as speed, feed, and depth of cut, cycle time, and number of
passes for CNC machines in Pu - 1