A Internship Report on

Koso India Private Limited

From – 27th Jan 2023 to 25th Feb 2023

By

Mr. Shreyas Jitendra Wani

Exam Seat No – T190470950

Guided By

Prof. R.J.Pawar

Bhujbal Knowledge City

MET’s Institute of Engineering

Department of Mechanical
Engineering[2022 – 2023]
 CERTIFICATE

This is to certify that Mr. Shreyas Jitendra Wani, have

successfully completed the INTERNSHIP work entitled “ Koso
India Private Limited, in the partial fulfilment of Bachelor of
Engineering - Mechanical Engineering, by Savitribai Phule
Pune University.
Date: / /2023

Place: Nashik

Prof. R.J.Pawar Examiner

Guide

Dr.M.P.Ray Dr. V.P.Wani

Head of the Department Principal
 ACKNOWLEDGEMENT
This acknowledges my sincere thanks to our INTERNSHIP
guide Prof.R.J.Pawar who helped me in selecting the seminar topic,
understanding of the subject, whose valuable guidance and
continuous encouragement throughout this work made it possible to
complete this task well in advance.

I am extremely grateful to. Prof. Dr. M.P.Ray, Head, Mechanical

Engineering Department, I also wish to express a deep sense of
gratitude to Prof. Dr.V.P.Wani , Principal, MET’s Institute of
Engineering for providing all facilities and every help for smooth
progress of INTERNSHIP work I am also thankful to other staff
members of our esteemed college, MET’s Institute of Engineering,
Nasik for their special attention and suggestions.
 INDEX
Sr.No Title Page No.
Cover Page
Certificate
Acknowledgement
Index
Abstract
1. Introduction 1
1.1 Safety Instructions 3
2.
2.1 Process of Production of Valve 4
3. Machine Shop 5
3.1 VTL MACHINE 5
3.2 HBM Machine 6
3.3 HMC Machine 7
3.4 CNC Machine 8
3.5 Casting Process 9
3.6 RDM Machine 10
4. Welding 11
4.1 Types of Welding 12
5. Types of Valve (Pressure Control Valve) 13
5.1Ball Valve 15
5.2Butterfly Valve 16
 5.3Globe Valve 17
5.4Choke Valve 18
5.5Angle Valve 18
6.
6.1 Control valve 19
6.2 Actuator 20
7.
7.1 Assembly 22
8. Types of Valve Testing 23
8.1 Testing Valve 24
8.2 Leakage Valve 25
8.3 Function Valve 26
9. Quality Inspection 27
9.1 QC (Quality Control) Instrument 28
10. Paint Shop 29
10.1 Blasting Process 30
10.2 Safety Precautions While Painting 31
10.3 Standard Coats Used While Painting 32
11. Valve Packaging and Dispatch 33
11.2 Packaging Process 34
11.2 Symbol used while Packaging 35
 ABSTRACT
As l am very fond of mechanical engineering. It was a great opportunity
for me to do Three weeks internship in Koso india Private Limited. The
internship was concentrated on the Valve. At the beginning of the internship
l had several queries in my mind regarding the different technologies and
Machines used in Koso india Private Limited and what skills are needed in
Industry. During my internship several queries are cleared by doing some
activities. The objective of this internship is to gather information about
the quick services and the major-minor problem that can be observed in
day-to-day life. In the Internship, I have learnt the rules and safety
instruction which helps me in understanding while working on Valve. So,
this internship was a great experience. I found out how much I am strong in
Mechanical field. I gained new knowledge and skills and met many new
people. I achieved many of my learning goals. I got insight into the work of
an Industry. The financing is an important factor and forces to be flexible
in attitude and approach. I learned more about the problems which I have
face while making of valves. Working together with the different
background peoples and by education these threats have to be approached
to succeed in my internship the sharing of knowledge, ideas and opinions
is of importance. There is still a lot of discover and other methods can be
improved. At last, this internship has given me new insights and motivation
to pursue a career in mechanical engineering.

Key Words:- Mechanical engineering , learning goals , Career in

Mechanical engineering.
1.INTRODUCTION
Mechanical engineering is the study of physical machines that may
involve force and movement. It is an engineering branch that
combines engineering physics and mathematics principles with
materials science, to design, analyze, manufacture, and maintain
mechanical systems.

1.1 Safety Instructions

1. Inform Supervisors of Unsafe Conditions
2. Use Equipment, Machines, and Tools Properly
3. Wear Safety Equipment (PPE)
4. Prevent Slips and Trips
5. Keep Work Areas and Emergency Exits Clear
6. Eliminate Fire Hazards
7. Avoid Tracking Hazardous Materials

8. Prevent Objects from Falling

9. Use Correct Posture when Lifting
10. Take Work Breaks Time to Time
2.1 Process of Production of Valve
1.Stored Material
2.Casting
3.Welding
4.Assembly
5.Testing
6. Quality check
7. Painting
8.Package & Dispatch
3.Machine Shop
A machine shop or engineering workshop is a room, building, or
company where machining, a form of subtractive manufacturing, is
done. In a machine shop, machinists use machine tools and cutting
tools to make parts, usually of metal or plastic (but sometimes of other
materials such as glass or wood).

3.1 VTL MACHINE

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. Maximum Rpm used in industry is 80 Rpm.
Process on VTL Machine
1.Plug Way 4. Turning
2.Butt Way 5.Facing
3.Flank 6. Groving
3.2 HBM Machine

In a horizontal boring machine, the work is supporting on a table which

is constant and the tool turns into a horizontal axis. A horizontal boring
machine can perform boring, reaming, turning, threading, facing,
milling, grooving, recessing and many other operations with suitable
tools.
3.3 HMC Machine

Horizontal machining occurs on a horizontal machining center (HMC),

which employs a spindle that is parallel to the ground floor. With a
horizontally oriented spindle, tools stick out of the side of the tool
holder and cut across the side of a workpiece, encouraging chips to fall
away from the table.
3.4 CNC Machine

It is a computerized manufacturing process in which pre-programmed

software and code controls the movement of production equipment.
CNC (Computing Numerical Control) machining controls a range of
complex machinery, such as grinders, lathes, and turning mills, all of
which are used to cut, shape, and create different parts and
prototypes.
3.5 Casting Process

Casting processes involve the use of molten material, usually

metal. This molten material is then poured into a mould cavity
that takes the form of the finished part. The molten material
then cools, with heat generally being extracted via the mould,
until it solidifies into the desired shape.

Weld Type
1.Butt Weld End (BWE)
2.Ring Type Joint (RTJ)
3.Socket Weld Hand (SWH)
4.Flange end (RF) / Surrection
3.6 RDM Machine

The radial drill of these machines possesses a large gear head that can move
alongside the radial arm. This specific drill maximises a cutting tool known as the
drill bit. Once the radial arm moves, it can effectively swing the drill head away,
enabling the placement of the workpiece on the machines' base.
Process in RDM
1.Drillilg
2.Rimming
3.Taping
4. Welding
Welding is a fabrication process that joins materials, usually metals or
thermoplastics, by using high heat to melt the parts together and
allowing them to cool, causing fusion. Welding is distinct from lower
temperature techniques such as brazing and soldering, which do not
melt the base metal (parent metal).

4.1 Types of Welding

i. Gas Metal Arc Welding (GMAW/MIG)

Also known as Metal Inert Gas or MIG welding, this process uses a thin wire as
an electrode. The wire heats up as it is fed through the welding instrument and
towards the welding site. Shielding gas must be used to protect the weld from
contaminants in the air.

Typically, this comes in the form of carbon dioxide, oxygen, argon or helium.
This method is often used to work on metals such as stainless steel, copper,
nickel, carbon steel, aluminum, and more. Of all the welding processes, this
one is most popular across the construction and automotive industries.

ii. Gas Tungsten Arc Welding (GTAW/TIG)

This type of welding process, also known as Tungsten Inert Gas or TIG welding,
is commonly used to weld together thin and non-ferrous materials like
aluminum, copper, lead, or nickel. It’s commonly applied to bicycle or aircraft
manufacturing.

Unlike other types of welding processes, TIG welding uses a non-consumable

tungsten electrode to produce the weld. You will still need an external gas
supply, usually argon or a mix of argon and helium.
iii. Shielded Metal Arc Welding (SMAW)

This type of welding process relies on a manual technique using a consumable

electrode coated in flux. This method tends to be most popular among home-
shop welders. This process is also more informally known as stick welding.

The nickname references the electrode used to weld the metal, which comes
in the form of a “stick.” Because shielded metal arc welding requires minimal
equipment, it’s one of the most low-cost processes around.

iv. Flux Cored Arc Welding (FCAW)

Similar to MIG welding, flux cored arc welding revolves around a continuous
wire feed process. There are two separate processes associated with flux cored
arc welding.

One involves the use of shielding gas while the other relies on self-shielding
agents produced when fluxing agents decompose within the wire.

4.2 basic welding joint types

1.Butt joint welding.

2.Tee joint welding.

3.Corner joint welding.

4.Lap joint welding.

5.Edge joint welding.

5.Types of Valve (Pressure Control Valve)
1. Ball Valve
2. Butterfly Valve
3. Globe Valve
4. Choke Valve
5. Angle Valve

5.1 Ball Valve

210C: Concentric Segmental Ball Valves (FLOWMAX C/Wafer)
This series is concentric segmental ball valve for modulating application. V-
notch cut at disc makes rangeability larger and creates shearing effect by disc
and seal ring. Therefore, suitable to large rangeability service and/or control of
fluids with fiber or slurry.

230C: Concentric Segmental Ball Valves

This series is same as 210C series except that the stem penetrates the body and
is supported by double gland packing. The stem's blow out force is set off in
this construction making it suitable to heavier services such as high pressure,
high temperature service because of heat expansion insulation design stem.
Ball Valve Assembly Components
1. Body
2. Body Cap
3. Ball
4. Shaft
5. Gland plate
6. Gl Flange
7. Gland Packing
8. Gasket
9. Gland Bush
5.2 Butterfly Valve
710C : Concentric PARA-SEAL Valves' (PARA-SEAL C)
This PARA-SEAL valve is high performance butterfly valve of high durability, high
seating performance. It has several different seal ring constructions suitable to
various service applications.
Butterfly Valve Assembly Components
1. Body
2. Body Cap
3. Plate
4. Shaft
5. Gland plate
6. Gl Flange
7. Gland Packing
8. Gasket
9. Gland Bush

VSOP (Visual Standard Operating Procedure)

Part Discription
1. Operating Procedure for Valve Point Shop
2. Operating Procedure of Whirling Elcometer Hygrometer(116A)
3. Instrument Used Is (ELCOMETER)
5.3 Globe Valve
The globe valve, different from ball valve, is a type of valve used for
regulating flow in a pipeline, consisting of a movable plug or disc element
and a stationary ring seat in a generally spherical body.

Globe Valve Assembly Components

1. Body
2. Bonet
3. Seat Ring
4. Plug
5. Disc Stack
6. Stem
7. Balance Cylinder
8. Body Stud
9. Retainer
5.4 Choke Valve
It has a small opening called a choke bean, which helps to reduce the
pressure as the liquids flow through it. The choke is designed to handle an
erosive service in the form of sand particles in the fluids.

5.5 Angle Valve

Angle valves are commonly used in boiler feedwater and heater drain
service and in piping schemes where space is at a premium and the valve
can also serve as an elbow.
6.1 Control valve
KOSO top-guided control valves are compact and simple structured.
They are usable in a broad scope of applications, including all cavitation-
free liquid services as well as steam and gas services that meet noise
regulations.
Aiming at quick delivery and low prices, 551T is limited to JIS 10K,
ANSI(JPI)150 lbs. with no optional features. 520T covers minimum flow
applications, with its small plug specially designed not to break off.
6.2 Actuators
1.Diaphgram
5200 : Pneumatic Diaphragm Actuators
This Series provides high performance, high power diaphragm actuators
of multi-spring type that are compact and light. Receiving pneumatic or
electric signals, the unit balances the force created when diaphragm is air-
pressured through positioner and the force of compressed spring, so that
the output shaft is controlled and placed at a set position.
Control of position by pneumatic signals (20 to 100Kpa) directly applied
on diaphragm is also possible. Combination with KOSO positioner
provides high accuracy position control.
2.Cylinders
6100LA

• 1 Piston type
• Valve stem and actuator output shaft connection is inside the
cylinder.

6200LA

• 2 Piston type
• Valve stem and actuator output shaft connection is inside the
cylinder.

6300LA

• 1 Piston type
• Valve stem and actuator output shaft connection is outside the
cylinder (in Yoke).
7.Assembly
Assembly is the process of combining individual components into a
finished product during manufacturing. An assembly may also refer to
a single-level bill of material (BOM), a multilevel BOM, or a top-level
BOM. Assemblies may be comprised of mechanical, electrical, or
software components.

i. Operating Procedure for Lapping of Valve Plug & Seat

ii. Assembly of Valve
iii. Assembly of Choke Valve
iv. Metal Sealed Ball Valve Assembly
v. Operating Procedure for Assembly of Choke Valve
vi. Valve Assembly Procedure
vii. Assembly of DSH

7.1 (PFD) Process Flow Chart

i. Raw Material
ii. Machining (Body)
iii. Actuator + Body (Assembly)
iv. Testing (Instrument + Instrument Mount + Inspection)
v. Final (Paint + Cleaning + All Procedure)
vi. QC (Quality check)
vii. Packaging
8. Types of Valve Testing

8.1 Leakage Testing

Leak testing is a procedure that inspectors use to determine
whether an object or system is functioning within a specific leak
limit. Leaks occur when there is a defect—a hole, crack, or some
other kind of flaw—in an object, allowing whatever the liquid or
gas it is holding to flow out.

Valve Testing Section

i. Cryogenic Test
ii. Dye Penetration Room

8.2 Function Testing

Functional testing is a type of testing that seeks to establish
whether each application feature works as per the software
requirements. Each function is compared to the corresponding
requirement to ascertain whether its output is consistent with the
end user's expectations.
8.3 Testing Types
i. Destructive Testing
Destructive testing (DT) includes methods where the material is
broken down in order to determine mechanical properties, such
as strength, toughness and hardness. Advantages of Destructive
Testing (DT).
Verifies properties of a material.
Determines quality of welds.

ii. Non Destructive Testing

Non destructive testing (NDT) is the process of inspecting, testing,
or evaluating materials, components or assemblies for
discontinuities, or differences in characteristics without destroying
the serviceability of the part or system. In other words, when the
inspection or test is completed the part can still be used.
9. Quality Inspection
Quality Inspection is an activity of checking, measuring, or testing one or
more product or service characteristics and comparing the results with the
specific requirements to confirm compliance. This task is executed by
skilled personnel, not by production workers

9.1 QC (Quality Control) Instrument

1. Varnier Calliper
2. Tape Gauge
3. Bor Gauge
4. OD Micrometer
5. ID Micrometer
6. Slip Gauge
7. Blade Micrometer
8. Dape Gauge
9. Plug Gauge
10. Ring Gauge
10. Paint Shop

10.1 Blasting Process

Blast cleaning helps in surface preparation by removing
contaminants before coating, painting or lining. Surface cleaning
removes rust and other contaminants which could cause problems
with paint adhesion, or in the most extreme cases, compromise
the integrity of the surface metal itself.
Anchor Profile 40-70 Microns.
10.2 Safety Precautions While Painting
• Goggles:
• Contact of paint with eye. ...
• Hand Gloves:
• Contact of liquid paint with skin should be avoided by
using proper hand gloves.
• Safety Equipments For Painting:
• Respiratory mask:
• Inhalation of solvent vapors or paint mist should be
avoided by using proper respiratory mask.
• Safety Equipments For Painting
10.3 Standard Coats Used While Painting
i. Paint 469
ii. Paint 473

Dry Type Paint Booth is used in company.

Process
1. Primer
Over coating period (6 to 24 hours) depends on temperature
2.Curing
Whenever Dust is present on Material sanding is done
3. (DFT) Dry Film Thickness
DFT meter is used to Measure Thickness

i. Zinc Primer (1Quota=50Microns)

(DFT) Dry Film Thickness – 300 Microns
ii. Intermidate
DFT 200 to 250 Microns
iii. Final
DFT 300 Microns
11.Valve Packaging and Dispatch

11.1 Packaging Procedure

1.Delivery Details
2.Order No
3.Item No
4.Add. of origin
5.Box weight sign
6.Box weight
7.Box size

Details
1. For export boxes
(ISPM 15) Fumigation Process is used for not getting affecting
by Bugs, Fungus, etc (Methyl Bromide) is used for Precaution.
2.Water Proofing Process
Aluminium foil is used or high density polyrate
Epirole is used for protection
3.Rust Prevention
Rust Prevention Oil is used (Cortec VPCI 369)
Bolted and cap is used for butt holes and hole
11.2 Symbols Used while Packaging