FOURESS ENGINEERING India.

PVT Ltd 2022

KNOWLEDGE IS POWER

SCHOOL OF MECHANICAL ENGINEERING

INTERNSHIP REPORT ON

In fulfilment of the internship about the Butterfly valve

FOURESS ENGINEERING INDIA LTD

Name Manish Kumar

SRN No R18ME122
Company name FOURESS ENGINEERING
INDIA PVT LTD
Department PU – 1
Joining Date 26-07-2023
End Date 16- 08-2023

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FOURESS ENGINEERING INDIA LTD

Peenya , 2nd Phase
Bangalore- 560058

CERTIFICATE
This is to certify that the internship in FOURESS ENGINEERING INDIA
PVT LIMITED is carried out by MANISH KUMAR(R18ME122) 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.

MR. RAMESH. N. M MR. Y N SHANKAR MURTHY

SENIOR MANAGER EXECUTIVE HR

FOURESS ENGINEERING FOURESS ENGINEERING

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ACKNOWLEDGEMENT

Interning at FOURESS INDIA PVT LTD. was a great learning experience and helped me grow, both as
a professional and as an individual.

Firstly, I would thank our DR. K. S. NARAYANASWAMY, Director of School of Mechanical

Engineering, REVA University, for always motivating me to learn something new.

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.

MANISH KUMAR

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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.

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TABLE OF CONTENT:

• ACKNOWLEDGEMENT.......................................................................................... 3

• EXECUTIVE SUMMARY.........................................................................................4

• COMPANY PROFILE............................................................................................... 6

• CHAPTER - 1

 About the departments

 Production Unit 1: Design team

 Production Unit 2: Machine shop

 Production Unit 3: Assembly line

 Production Unit 4: Fabrication

 Production Unit 5: Inserts

• CASE STUDY -1 .................................................................................................... 19

• INTERNSHIP OUTCOMES

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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.

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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

GLOBAL PRESENCE INDUSTRIES SERVED

Algeria New Zealand Power

Australia Norway Steel & Metallurgical Plants
Bangladesh Panama Water Supply & Sewage
Belgium Saudi Arabia Cement
Brazil Singapore Oil & Gas
Chile Spain Refineries
China Sri Lanka Petrochemicals
Cuba Sudan Chemical & Fertilizers
Egypt Syria Sugar Plants
Germany Taiwan
Hongkong Thailand
Hungary Turkey

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COMPANY OVERVIEW

• Fouress Engineering (India) Private limited is a non-government company, incorporated on 25 Jun

1971. It's a private unlisted company and is classified as ‘company limited.

• 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.

• Global leaders in valves production.

• First or Second in every market they serve.

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CHAPTER 1. BRIEF INTRODUCTION TO VALVES

• 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.

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CHAPTER 1.1. FOURESS ENGINEERING VALVES AND TYPES

• 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

Control valves Isolation

Angle valves Butterfly valve

Globe valves Spherical valve

Ball valves Check valve (NRV)

Gate valve Knife gate valve

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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.

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ABOUT THE DEPARTMENTS

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.

Production Unit 1: Design Team

• 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.

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Production Unit 2: Production Machine Shop (Butterfly valve )

• 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.

EXPLODED VIEW OF BUTTERFLY VALVE:

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Manufacturing machinery:

1. RVTL (Russian vertical lathe)

• Vertical turning lathes (VTL) are machines that orient the spindle in the vertical plane in a fixed position.
The workpiece then spins, moving up and down to put it in line with the cutting head. These machines
are less complex than horizontal lathes. This machining option is best for pieces that focus on shaping a
single side of a part. While not suited for high-production runs, they excel at taking heavy cuts on
medium and large parts.

• There are certain applications where a vertical turning lathe machine has an advantage over other
machining solutions. We take advantage of this to produce better parts and more efficient machine piece.
This can handle operations of 1000 to 2400mm. Used for body and disc manufacturing.

• Turning Processes our machines can handle:

• Boring
• Cutting
• Drilling
• Facing
• Internal forming
• Knurling
• Necking

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2. GVTL (German vertical turning lathe)

• Vertical turning lathes that use the main
spindle to load and unload themselves are
finding increasing acceptance as multitasking
capabilities make them efficient processing
centres for producing chucked parts.
• Vertical turning lathes give foundries with
machine shops as well as those that
outsource machining the ability to cut
bigger and heavier castings
• This machine is used for manufacturing
Body and disc of the valve and key way and
mainly used for 600 to 800mm.

3. Pegard boring machine (horizontal)

• This PEGARD Boring Machine was manufactured

in 1972 and has a production record of
approximately 32250 working hours.
• Boring machine, device for producing smooth and
accurate holes in a workpiece by enlarging existing
holes with a bore, which may bear a single cutting
tip of steel, cemented carbide, or diamond or may
be a small grinding wheel. Single-point tools,
gripped in a boring head attached to a rotating
spindle, are moved circularly against the sides of
the existing holes. The diameter of the hole swept
out by the tool is controlled by adjustment of the
boring head.
• The cutting tool is normally single point which are
made of M2 and M3 high-speed steel
• Forming operation
• Machining flat surface
• Taper boring operation
• Turning cylindrical surface

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4. CNC Plasma Cutting Machine

• Plasma cutting is a process that cuts through electrically conductive materials by means of an
accelerated jet of hot plasma. Typical materials cut with a plasma torch include steel, stainless
steel, aluminium, brass and copper, although other conductive metals may be cut as well. Plasma
cutting is often used in fabrication shops, automotive repair and restoration, industrial construction,
and salvage and scrapping operations. Due to the high speed and precision cuts combined with low
cost, plasma cutting sees widespread use from large-scale industrial CNC applications down to small
hobbyist shops.

• Plasma cutting is an effective way of cutting thin and thick materials alike. Hand-held torches can
usually cut up to 38 mm (1.5 in) thick steel plate, and stronger computer-controlled torches can cut
steel up to 150 mm (6 in) thick. Since plasma cutters produce a very hot and very localized "cone" to
cut with, they are extremely useful for cutting sheet metal in curved or angled shapes.

• The arcs are generated in a three-step process. A high voltage spark briefly ionizes the air within the
torch head. This makes the air conductive and allows the "pilot arc" to form. The pilot arc forms within
the torch head, with current flowing from the electrode to the nozzle inside the torch head. The pilot
arc burns up the nozzle, a consumable part, while in this phase. The air then blows the plasma out the
nozzle towards the work, providing a current path from the electrode to the work. When the control
system senses current flowing from the electrode to the work, it cuts the electrical connection to the
nozzle.

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Production Unit 3. Assembly Line

• An assembly line is a manufacturing process (often called a progressive assembly) in which parts
(usually interchangeable parts) are added as the semi-finished assembly moves from workstation to
workstation where the parts are added in sequence until the final assembly is produced. By mechanically
moving the parts to the assembly work and moving the semi-finished assembly from workstation to
workstation, a finished product can be assembled faster and with less labour than by having workers
carry parts to a stationary piece for assembly.

Production Unit 4. Fabrication

• Mild Steel Fabrication is made utilizing excellent paint just as combinations. These items are utilized
in different businesses, and we offer these items at industry driving costs to customers. Our items are
exceptionally known for their viable execution, and we offer these items in different examples, sizes,
structures and shapes and these items are effectively accessible in the market. A predominant quality
mills steel fabrication is done on different kinds of mild steel (MS) sections and plates. We have all the
accessible assets and a profoundly proficient group of laborers with us. Quality affirmation is a
significant need, and we profoundly trust in making our client fulfilled. Fabrication is done in an
altered way to fulfil each customer's needs in the most ideal way. We likewise put stock in conveying
our administration in a characterized stipulated period.

• The valves are usually made from mild steel. A body disc covers most of the valve's parts.

• Main Types of Paint Used with Steel Standard primers Specialty paints 1. Zinc 2. Epoxy 3.
Polyurethane

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Production Unit 5. Inserts

• 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

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Case study-01

. Body
An initial pre-shaped material cleaned. A turning process is done after cleaning. Turning is the method of
removing excess material by cutting using a lathe or a turning machine. It involves attaching the pre-
shaped body to a mount and to the turning machine. This machine rotates at a high speed. While it rotates,
a single-point cutter cuts the body into the desired and specific shaped. Other than that, turning can also
create grooves, holes, among others.

The next step is to add a plating metal, usually, copper to different sections of the body. Copper plating
ensures complete and proper sealing of the body.

The next step is the polishing of the body. Then, technicians create the threads that allow attachment of
certain valve parts to other components or the pipes. Valves need holes so holing also happens after this.
Take note that each valve has different hole sizes, depending on the requirement. This is where regulations
and standards come into play.

Technicians then paint the valves with Teflon or other types of elastomer. After painting, baking ensues.
Teflon bonds with the body through baking

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Seat
The seat undergoes the same
process as the body. Since the
seat is inside the body and as
part of its valve function- for
better sealing- it needs perfect fit
to its attachment. Whereas the
body only has Teflon, the seat as
an additional rubber wrapping
to ensure tight fitness.

Stem
As in the case of the stem, it does
not need to have much
manufacturing. Rather, cutting
these in the right dimensions is
important

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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

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