SUMMER INTERNSHIP AT

FLOTEC-TECHNOSMART(INDIA)PVT.LTD.

A PROJECT REPORT

Submitted by

MIHIR ZOPE

210160119040

In partial fulfilment for the award of the degree of

BACHELOR OF ENGINEERING
in

Mechanical Engineering Government Engineering

College , Modasa

Gujarat Technological University, Ahmedabad

[July-2024]
 Government Engineering College, Modasa
Shamlaji Road, Modasa, Gajan, Gujarat 383315

CERTIFICATE
This is to certify that the project report submitted along with the project entitled SUMMER
INTERNSHIP AT Flotec Technosmart(INDIA) PVT. LTD. been carried out By MIHIR
ZOPE under my guidance in partial fulfilment for the degree of Bachelor of Engineering in
Mechanical, 7th Semester of Gujarat Technological University, Ahmadabad during the academic
year 2024-25.

Internal guide Head of the Department

i
 DECLARATION

We hereby declare that the Internship report submitted along with the SUMMER
INTERNSHIP AT Flotec Technosmart(INDIA) PVT.LTD. submitted in partial
fulfillment for the degree of Bachelor of Engineering in Mechanical to Gujarat
Technological University, Ahmedabad, is a bonafide record of original project work
carried out by me At Flotec technosmart(INDIA)PVT.LTD. under the supervision of
NARENDRA OZA and that no part of this report has been directly copied from any
student’s reports or taken from any other source, without providing due reference.

Name of the Student Sign of Student

Mihir Zope

ii
INTERNSHIP COMPLITION CERTIFICATE

iii
 ACKNOWLEDGEMENT
I would like to extend my heartfelt gratitude to everyone who made this internship a valuable
and enriching experience.
First and foremost, I am immensely grateful to Flotech Tecnosmart(INDIA) Pvt. Ltd. .for
providing me with the opportunity to undertake this internship. I am thankful to Mukesh Patil,
my supervisor, for their unwavering support, guidance, and encouragement throughout my
internship. Their insights and expertise were instrumental in enhancing my learning experience.
I would also like to express my sincere appreciation to the entire Workshop team for their
cooperation and assistance. Their willingness to share their knowledge and provide feedback has
been invaluable.
A special thank you to Gujarat Technological University and my faculty advisor Mittal Patel, for
their support and for facilitating this internship. Their advice and encouragement helped me
navigate through this journey.
Finally, I am grateful to my family and friends for their continuous support and understanding
during this period.
This experience has been profoundly beneficial for my personal and professional growth, and I
am thankful to everyone who contributed to making it a success

iv
 ABSTRACT
This report documents the experiences and insights gained during my internship at Flotech Techno
smart(INDIA) Pvt. Ltd. Where I worked as a Intern from 29th June 2024 to 12th July 2024. The
primary focus of this internship was to enhance my practical knowledge and skills in Mechanical
Field with particular emphasis on Valve Servicing.
Throughout the internship, I was involved in various type of valves. These allowed me to apply
theoretical concepts learned in my academic studies to real-world scenarios, fostering a deeper
understanding of Fluid dynamics and high pressure.
Additionally, I collaborated with professionals from diverse backgrounds, which enhanced my
teamwork and communication skills. Regular feedback sessions and mentorship from my
supervisors were instrumental in my professional development, providing valuable insights into
industry standards and practices.
This Internship provide a transformative experience that bridged the gap between academic learning
and Practical application, equipping me with the skill and confidence necessary for a successful
career in valve Technician.

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 LIST OF FIGURE

Figure 1-1 Company Logo.................................................................................................................................. 1

Figure 1-2 Work-Shop ........................................................................................................................................ 1
Figure 2-1 Test Bench ........................................................................................................................................ 3
Figure 2-2 Air Compressor ................................................................................................................................. 4
Figure 2-3 Air And Hydraulic Boosters ............................................................................................................. 5
Figure 2-4 Lapping Kit ....................................................................................................................................... 6
Figure 2-5 Seat Leak Clamp ............................................................................................................................... 6
Figure 2-6 Hydro Pump ...................................................................................................................................... 7
Figure 3-1 Schematic Diagram ........................................................................................................................... 8
Figure 3-2 Lapping Process ................................................................................................................................ 9
Figure 3-3 Calibration Process ......................................................................................................................... 12
Figure 3-4 Assembly Department ..................................................................................................................... 14
Figure 5-1 Valve Testing .................................................................................................................................. 20
Figure 5-2 Testing with Air .............................................................................................................................. 22
Figure 5-3 Testing with Water .......................................................................................................................... 23
Figure 5-4 gate Valve Testing With water........................................................................................................ 25
Figure 5-5 Testing of Breather Valve ...............................................................................................................

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 TABLE OF CONTENT

CERTIFICATE ............................................................................................................................................... i
DECLARATION............................................................................................................................................ ii
INTERNSHIP COMPLITION CERTIFICATE ........................................................................................ iii
ACKNOWLEDGEMENT ........................................................................................................................... iv
ABSTRACT ................................................................................................................................................... v
CHAPTER 1: OVERVIEW OF THE COMPANY ...................................................................... 1
1.1. HISTORY : ........................................................................................................................................... 1
CHAPTER 2: EQUIPMENT AND TOOLS.................................................................................. 3
2.1. TEST BENCH : .................................................................................................................................... 3
2.2. AIR COMPRESSOR : .......................................................................................................................... 4
2.3. AIR AND HYDRAULIC BOOSTERS : .............................................................................................. 4
2.4. LAPPING KIT : ................................................................................................................................... 5
2.5. SEAT LEAK CLAMPS : ...................................................................................................................... 6
2.6. HYDRO PUMP : .................................................................................................................................. 7
CHAPTER 3: PROCESS BEING CARRIED IN THE COMAPANY ....................................... 8
3.1 MANUFACTURING PROCESS : ....................................................................................................... 8
3.1.1. LAPPING PROCESS: ................................................................................................................... 8
3.1.2. CALIBRATION PROCESS: ....................................................................................................... 10
3.2. WORK CARRIED OUT IN EACH DEPARTMENT : ...................................................................... 13
3.2.1. TESTING DEPARTMENT : ....................................................................................................... 13
3.2.2. ASSEMBLY DEPARTMENT : ................................................................................................... 13
CHAPTER 4: INTRODUCTION TO PROJECT ...................................................................... 15
4.1. PURPOSE : ........................................................................................................................................ 15
4.2. ROLES AND RESPONSIBILITIES : ................................................................................................ 15
4.2.2. SAFETY PRECAUTIONS : ....................................................................................................... 16
4.2.3. GROUP DEPENDENCIES : ....................................................................................................... 17
CHAPTER 5: GENERAL TESTING PROCESSES .................................................................. 18
5.1. TESTING PROCESS FOR THE PRV/PSV : ..................................................................................... 19
5.1.1. PRESSURE TESTING WITH AIR :........................................................................................... 19
5.1.2. PRESSURE TEST WITH THE WATER :................................................................................... 22
5.3. TESTING PROCESS FOR GATE VALVE : ..................................................................................... 23
5.4. TESTING PROCESS FOR CONTROL VALVE : ............................................................................. 25
5.4.1. PRESSURE TESTING :.............................................................................................................. 25
5.4.2. FUNCTIONAL TESTING : ........................................................................................................ 25
5.5. BREATHER VALVE TESTING PROCESS : .................................................................................... 25
CHAPTER 6: CONCLUSION ..................................................................................................... 28
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 6.1. INTERNSHIP OBJECTIVES : .......................................................................................................... 28
6.2. INTERNSHIP ACTIVITIES : ............................................................................................................ 28
6.3. KEY LEARNINGS : .......................................................................................................................... 28
6.4. CONCLUSION : ................................................................................................................................ 28
REFERENCES ............................................................................................................................................ 29

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 CHAPTER 1: OVERVIEW OF THE COMPANY

1.1. HISTORY :
The Company had a humble start with major capital investment equipped with a single test bench
and a hand full of tools for reconditioning and testing of Pressure Relief Valves as a proprietary
firm under the name of FLOTEC ENGINEERING SERVICES.

Figure 1-1 Company Logo

Flotec Engineering Services came into existence in the year 1994, with thorough knowledge
and adequate experience in the relevant field and gradually became a part and parcel of the
growing industrial belt in Surat, Gujarat. Pressure Relief Valve, though being an instrument
which plays the critical role in safety of a process industry in an extreme emergency situation,
when all other system controls to prevent the increase in pressure in a system or vessel become
inoperative, the instrument was never given the due importance as needed or deserved.

Figure 1-2 Work-Shop

Soon, our wings of service got spread into larger areas extending our services to wider
sector of industries such as Oil & Gas, Petrochemicals, Refineries, Fertilizers,
Chemical and Steel etc. Our presence on offshore platforms since years is considered to
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ID -55278 CHAPTER 1: OVERVIEW OF THE COMPANY

be an additional credibility of the company. The growth in the specialized field continued
and we attained best test facilities and excellent manpower to meet the increasing quality
requirement of our valued customers.
Flotec Engineering Services, acquired an ISO 9001-2000 certification and later on in the
path, converted to an ISO 9001 – 2015 certified company and is proud to have the largest
number of portable test facilities in India for Pressure Safety Valves, supported with
entire range of hand tools and accessories, lapping and reconditioning facilities, utility
vehicles and communication gadgets which enable us to provide ultimate protection to
intelligent investment of our customers in any eventuality in the shortest possible time.
Self-developed test facilities, high pressure air and hydro booster units, specially developed
lapping tools for gate, globe & non-return valves, ball grinding/ polishing attachments,
fabrication of spare parts with the unlimited support of a Synergic Team of experts have led
us to the wider field of repair & servicing of all types of industrial valves, apart from the
unchallenged mastery we possess in Pressure Relief Valves, the ultimate protective
device of any process industry. Our full-fledged workshop provides fabrication and
machining support to precession requirement of the job Apart from the job of reconditioning
of valves and equipment, we manufacture and supply customized Test Facilities for Pressure
Safety Valves, Breather Valves and Control Valves which have occupied strategic roles in
various corporate industries.
FLOTEC ENGINEERING SERVICES have slowly transformed from a
Proprietorship firm to Private Limited firm in the year 2013, to widen the service base
and enhancing the manufacturing capability of the organization to carry the company to the
pinnacle of success, by offering the best and genuine products & services to our valued
customers and now known as…. FLOTEC TECHNOSMART (INDIA) PVT. LTD.

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CHAPTER 2: EQUIPMENT AND TOOLS

2.1. TEST BENCH :

PSV Test Benches of various models are the culmination of our extensive development effort
carried out based on our own long practical experience in the field of reconditioning and
testing of Valves, conforming to applicable codes & standards.
Test Benches, though are The standardized products of the company, Which Customized
according to customer's special requirements and engineering details are given prime
importance and are always incorporated in the final design, making it a customized product.
Our Single Post and Multi Post PSV Test Benches are ergonomically designed to
accommodate Pressure Safety Valves, irrespective of its make, type or class and the
mechanical features making it an independent and ever ready reliable unit without the support
of any kind of external energy in the event of an emergency.
Proud and satisfied owners of our test benches in various industrial sectors are spread across
the country and abroad, making us one of the prominent players in the field.

Figure 2-1 Test Bench

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2.2. AIR COMPRESSOR :

Air compressor skid supplied along with the PSV test bench ensures the self reliability of the
Test Bench making it completely independent equipment to provide trouble free performance
for years to come.
Air compressor skid comprises of a high pressure air compressor, a refrigerated air dryer and
storage cylinders which will serve as an independent supply source for PSV test Bench for
testing of Pressure Safety Valves.
The pneumatically operated Air and Hydro boosters are driven by the continuous supply of
low pressure air stored in cylinders, through pressure regulators and refrigerated air dryer
fitted at the discharge route of the air compressor.

Figure 2-2 Air Compressor

2.3. AIR AND HYDRAULIC BOOSTERS :

Light weight, compact & portable, a suitable substitute for commercial nitrogen cylinders,
high pressure air compressors or hydraulic pumps for testing valves and equipment’s.
Pneumatically operated unit facilitates controlled discharge and is safe for flame proof
applications/locations.
Low maintenance and easy operation makes it a user friendly product.
Air and Hydraulic Boosters are manufactured and supplied in various models depending upon
the discharge pressure requirements of the specific buyer.

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ID -55278 CHAPTER 2: EQUIPMENT AND TOOLS

Supplied as an independent unit or as a comprehensive high pressure pneumatic hydraulic

testing unit enclosed in an aesthetically designed metallic portable panel, with operational
controls, for easy and convenient mobility to desired locations.

Figure 2-3 Air And Hydroulic Boosters

2.4. LAPPING KIT :

Understanding the utmost importance of seat tightness of Pressure Safety Valves in a process
industry, and with our practical experience in the field of reconditioning and testing of
Pressure Relief Valves for the past more than 2 decades, we, at FLOTEC has come out with
a set of lapping blocks of various sizes with best supporting consumables, which would
facilitate the repairer to obtain perfect flatness of valve seats with maximum precision. These
lapping plates and rings can be used for in – situ lapping of nozzles and also to lap various
sizes of thermal balanced disc of Boiler Safety Valves.
All these precision plates, rings & specially selected lapping accessories are aesthetically
packed in a specially designed stainless steel carry box for easy portability.

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ID -55278 CHAPTER 2: EQUIPMENT AND TOOLS

Figure 2-4 Lapping Kit

2.5. SEAT LEAK CLAMPS :

Company is also providing the best solution to have a foolproof testing of seat tightness of
Pressure Relief Valve eliminating the age old method of covering the outlet of valve with G‘
clamps or with any other method which allows the tester to manipulate the result.
The light weight clamps designed by FLOTEC provide centralized clamping, ensuring leak
proof fitting with soft seated flange face.

Figure 2-5 Seat Leak Clamp

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ID -55278 CHAPTER 2: EQUIPMENT AND TOOLS

2.6. HYDRO PUMP :

Adequate height facilitates ease in operation. Longer and stronger handle for effortless
operation. Powder coated for longer rust free life. Available in pressure ranges – 100 | 200 I
300 kg/cm2.Replaceable piston seal bush for higher sealing efficiency. Sturdy, wide and
extended base frame offers better stability. Soft seated NRVs ensure perfect sealing and ease
in maintenance. A Hydro Pump to give you maintenance free service.

Figure 2-6 Hydro Pump

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ID -552785

CHAPTER 3: PROCESS BEING CARRIED IN THE

COMAPANY

3.1 MANUFACTURING PROCESS :

Manufacturing processes transform raw materials into finished products through a series of structured
steps. These steps typically begin with product design and planning, where detailed specifications and
process plans are developed. Raw materials are then selected based on the product requirements and
procured from suppliers. The actual manufacturing involves various techniques such as casting,
machining, forming, joining, and additive manufacturing to shape and assemble the product.

Quality control is integral to ensure that the finished products meet required standards and
specifications, involving inspections and tests. Once products are manufactured, they are
packaged and distributed to customers. Continuous maintenance of equipment and ongoing
process improvements help enhance efficiency and product quality. Compliance with safety
regulations and industry standards is essential throughout the manufacturing process to ensure
safety and regulatory adherence.

Figure 3-1 Schematic Diagram

3.1.1. LAPPING PROCESS:

It includes 150,320,2000 sand paper, also different types of lapping powder and
lapping oil commonly aluminium oxide is used as lapping Powder Lapping is a

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ID -55278 CHAPTER 3: PROCESS BEING CARRIED IN THE COMAPANY

precision machining process used to achieve high surface finish and flatness on a
variety of materials, especially metals, ceramics, and glass. Here’s how it works:
1. Process Overview: Lapping involves rubbing two surfaces together with an
abrasive and a carrier fluid or paste between them. The abrasive particles,
typically diamond or aluminium oxide, are suspended in a carrier such as oil or
water-based fluids.
2. Equipment: The primary equipment used in lapping is a lapping machine or a
lapping plate. The plate is typically a large, flat surface made of materials like
cast iron or steel, which is extremely flat and has a fine surface texture.
3. Operation :
o The workpiece (the material to be lapped) and the lapping plate are
brought into contact with each other.
o The abrasive slurry is applied between them, and the workpiece is moved
in a reciprocating or rotating motion relative to the lapping plate.
o Pressure is applied uniformly to ensure even material removal and to
achieve the desired surface finish.
4. Material Removal: Lapping removes material very slowly but effectively. It is
capable of removing only a few micro-meter of material to achieve the desired finish.
This slow material removal process helps in achieving high precision and smooth
surface finishes.

Figure 3-2 Lapping Process

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5.Benefits:
o High Precision: Lapping can achieve very tight tolerances and flatness requirements.
- Surface Finish: It produces extremely smooth and flat surfaces that are free from
scratches and other imperfections.
o Versatility: It can be used on a wide range of materials, including brittle ones like
ceramic.

6. Applications:
o Lapping is commonly used in the manufacturing of precision optical components,
semiconductor wafers, bearings, valve seats, and other parts where high precision and
smooth surfaces are critical.
o It is also used in the production of tools and dies where achieving precise dimensions
and surface finish is essential.
7. Limitations:
o Time-consuming: Lapping is a slow process compared to other machining methods
due to its precision nature.
o Initial Flatness Requirement: The lapping plate must be initially flat for effective
operation, which can be a limitation in some setups.
o In essence, lapping is a precise and effective method for achieving high-quality
surface finishes and dimensional accuracy, making it indispensable in industries
requiring exacting standards for their products.

3.1.2. CALIBRATION PROCESS:

Calibration is the process of adjusting and fine-tuning an instrument or system to ensure its
accuracy and precision in measurement. It typically involves comparing the instrument’s
output against a known standard or reference and making necessary adjustments to minimize
discrepancies. This process ensures that the measurements made by the instrument are as
close as possible to the true values. Calibration is crucial in various fields, including scientific
research, manufacturing, and quality control, where precise measurements are essential for
reliability and consistency.
Calibration is the process of comparing a measuring instrument's output to a known
standard to ensure accuracy. It's essential in various fields, from manufacturing to healthcare,
to guarantee reliable measurements.
Steps in Calibration
1. Calibration Scope:

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ID -55278 CHAPTER 3: PROCESS BEING CARRIED IN THE COMAPANY

o Identify the instrument or system to be calibrated.

o Determine the parameters to be calibrated (e.g., temperature, pressure,
voltage).
o Specify the calibration range (minimum and maximum values).
o Define the calibration interval (how often calibration is required).
2. Select Calibration Standards:
o Choose reference standards traceable to national or international standards.
o Ensure the standards have higher accuracy than the instrument being
calibrated.
3. Prepare for Calibration:
o Gather necessary equipment (calibrators, data acquisition systems, etc.).
o Establish environmental conditions (temperature, humidity, etc.) as required.
o Prepare calibration procedures and documentation.
4. Calibration Procedure:
o Apply known input values to the instrument.
o Compare the instrument's output to the reference standard.
o Calculate the deviation between the instrument's reading and the standard
value.
o Adjust the instrument (if possible) to correct the deviation.
o Repeat the process at multiple points within the calibration range.
5. Data Analysis and Reporting:
o Analysed the calibration data to determine instrument accuracy and
uncertainty.
o Generate a calibration certificate documenting the results.
o Identify any trends or patterns in the data.
6. Corrective Action:
o If the instrument is out of tolerance, take corrective action (repair, adjustment,
or replacement).
o Re-calibrate the instrument after corrective action.

7. Calibration Record Keeping: Maintain detailed records of

calibration activities, including:
o Calibration dates
o Calibration results
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ID -55278 CHAPTER 3: PROCESS BEING CARRIED IN THE COMAPANY

Corrective actions
o
o Calibration certificates
Types of Calibration
o Static Calibration: Measures the instrument's response to steady-state inputs.
o Dynamic Calibration: Evaluates the instrument's response to changing inputs.
o In-Situ Calibration: Calibrates the instrument in its operating environment.
o External Calibration: Calibrates the instrument in a controlled laboratory
environment.
Calibration Intervals
Calibration frequency depends on factors like:
o Instrument criticality
o Usage
o Environmental conditions
o Stability of the instrument

Figure 3-3 Calibration Process

Importance of Calibration
o Ensures accurate measurements
o Improves product quality and consistency
o Reduces waste and rework
o Complies with regulatory standards
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Protects against liability

o
Common Calibration Challenges
o Cost
o Time consumption
o Access to appropriate standards
o Maintaining calibration records
o Ensuring operator competence
Additional Considerations
o Uncertainty: The measure of doubt about the result of a measurement.
o Traceability: The ability to link a measurement result to international standards.
o Calibration Laboratory Accreditation: Provides assurance of technical
competence.

3.2. WORK CARRIED OUT IN EACH DEPARTMENT :

3.2.1. TESTING DEPARTMENT :

The Valve Testing Department plays a critical role in ensuring the reliability and safety of
valve systems used in various industries. This department is essential for conducting rigorous
performance assessments and quality control checks to guarantee that valves operate within
their specified parameters. Proper valve testing helps to identify any deficiencies or
malfunctions before the valves are deployed in critical applications, thereby preventing
potential failures that could lead to costly downtime or safety hazards.

Furthermore, valve testing ensures compliance with industry standards and regulatory
requirements, which is crucial for maintaining operational integrity and meeting legal
obligations. By performing detailed functional tests, pressure tests, and leak tests, the
department verifies that valves can withstand the operational pressures and environmental
conditions they will encounter. This thorough approach not only enhances the durability and
efficiency of valve systems but also contributes to the overall safety and reliability of
industrial processes.

3.2.2. ASSEMBLY DEPARTMENT :

The Assembly Department is crucial for ensuring safety and reliability in the final
products by adhering to precise assembly protocols. This department focuses on conducting
thorough safety inspections and quality control measures to ensure that all components are
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correctly assembled and meet stringent standards. Proper assembly is essential to avoid
hazards and malfunctions that could lead to serious safety risks or operational failures.
When assembly is not performed correctly, it can result in a range of severe safety
issues and operational problems. Inadequate assembly can lead to structural failures, leakages,
or malfunctions that pose risks to personnel and equipment. These issues not only
compromise the safety of operations but can also result in costly downtime, repair expenses,
and potential regulatory penalties. Therefore, the Assembly Department’s commitment to
meticulous assembly processes and adherence to safety protocols is essential for preventing
these critical problems and ensuring the overall integrity and reliability of the final products.

Figure 3-4 Assembly Department

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CHAPTER 4: INTRODUCTION TO PROJECT

4.1. PURPOSE :
Protection of Industrial Installations from catastrophic explosions due to over pressure
in pipelines and pressure vessels.

Eradication of false certification for mere documentation without dedication and

justification, the very reason for dangerous situations.

Flawless performance of various types of valves, reducing downtime, ensuring continuity in

production.

4.2. ROLES AND RESPONSIBILITIES :

Roles and Responsibilities During Valve Servicing

1. Service Technicians:
o Preparation: Ensure the work area is prepared, clean, and free of hazards.
o Isolation: Implement lockout/tagout procedures to isolate the valve from the
system.
o Inspection: Inspect the valve and tools before starting work.
o Servicing: Perform servicing tasks according to manufacturer guidelines and
company procedures.
o Testing: Test the valve post-servicing to ensure proper functionality and check for
leaks.
o Documentation: Record all servicing activities, observations, and any issues
encountered.
2. Supervisors:
o Planning: Oversee the planning and scheduling of valve servicing tasks.
o Coordination: Ensure coordination among various teams (e.g., maintenance,
operations).
o Safety Compliance: Monitor adherence to safety procedures and regulations.
o Training: Provide or ensure that appropriate training and resources are available
for service technicians.
o Approval: Approve lockout/tagout procedures and any required permits.
3. Safety Officers:
o Risk Assessment: Conduct risk assessments and identify potential hazards.
o Safety Procedures: Ensure that all safety procedures and PPE requirements are
followed.

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ID -55278 CHAPTER 4: INTRODUCTION TO PROJECT

o Emergency Response: Develop and communicate emergency response plans for

potential incidents.
4. Maintenance Engineers:
o Technical Support: Provide technical support and expertise on valve specifications
and servicing procedures.
o Resource Allocation: Ensure that the necessary tools, parts, and materials are
available for servicing.
o Problem Solving: Assist with troubleshooting and resolving any issues
encountered during servicing.
5. Operations Team:
o System Shutdown: Coordinate system shutdowns and isolation of the valve.
o Communication: Communicate with service technicians about system status and
any operational concerns.
o Verification: Verify that the valve servicing is completed and that the system is
safe to restart.

4.2.2. SAFETY PRECAUTIONS :

Safety Precautions for Servicing Valves

1. Personal Protective Equipment (PPE):
o Wear safety goggles to protect your eyes.
o Use gloves to prevent cuts and burns.
o Ensure appropriate footwear (safety shoes) and clothing.
2. Isolation and Lockout/Tagout:
o Ensure the valve is isolated from any live systems.
o Implement lockout/tagout procedures to prevent accidental operation.
3. Pressure Relief:
o Bleed off any residual pressure from the valve before servicing.
o Verify that the system is depressurized.
4. Tools and Equipment:
o Use the correct tools for the job to prevent damage.
o Inspect tools for damage before use.
5. Work Area:

o Keep the area around the valve clean and free of obstacles.
o Ensure adequate lighting to see clearly.
6. Valve Handling:
o Handle valves carefully to avoid dropping or damaging them.
o Use lifting equipment if the valve is heavy.
7. Check for Leaks:
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o After servicing, check for leaks around the valve.

o Test the valve function to ensure proper operation.
8. Follow Procedures:

o Adhere to the manufacturer’s servicing instructions and company procedures.

o Report any irregularities or issues immediately.
9. Training and Authorization:
o Ensure only trained and authorized personnel perform valve servicing.
10. Emergency Preparedness:
o Be familiar with emergency procedures in case of accidents or spills.

4.2.3. GROUP DEPENDENCIES :

1. Coordination Between Teams:

o Service Technicians rely on Supervisors and Operations Team for system isolation
and shutdown.
o Maintenance Engineers work with Service Technicians to ensure proper tools and
parts are available.
2. Safety and Compliance:
o Safety Officers depend on Service Technicians and Supervisors to follow safety
protocols and use PPE.
o Supervisors depend on Safety Officers for guidance on safety measures and
emergency procedures.
3. Documentation and Communication:
o Service Technicians need to communicate with Supervisors and Maintenance
Engineers about any issues encountered.
o Operations Team must stay informed about the status of the servicing to manage
system operations accordingly.
4. Emergency Preparedness:
o All teams must be aware of and prepared for emergency response plans provided
by Safety Officers.

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CHAPTER 5: GENERAL TESTING PROCESSES

The fundamental tests typically performed on valves after servicing, irrespective of their
specific type:
1. Visual Inspection:

o External and internal components examined for damage, wear, corrosion, or

foreign matter.
o Dimensional checks to ensure compliance with specifications.
o Dimensional Checks Valve body, stem, and other components measured to verify
they meet design tolerances.
2. Pressure Testing:
o Valve subjected to specific pressure to check for leaks and structural integrity.
o Types include hydrostatic, pneumatic, and hydraulic testing.
3. Seat Testing :

o Evaluates the sealing performance of the valve seat.

o Involves applying pressure to the valve while it's in the closed position.
4. Stem Packing Test :

o Checks the effectiveness of the packing to prevent leakage around the valve stem.
5. Actuation Test :

o Verifies the valve's ability to open and close smoothly and completely.
o Includes cycle life testing for specific valve types.
6. Torque Test :

o Measures the force required to operate the valve.

o Ensures proper operation and prevents damage.
7. Leakage Test :

o Identifies any leaks in the valve body, stem, or seat.

o Methods include bubble test, dye penetrant test, and helium mass spectrometry.
8. Performance Testing :

o Evaluates valve performance under specific operating conditions.

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o Includes flow coefficient (Cv) testing, pressure drop measurement, and response
time testing.

Figure 5-1 Valve Testing

Additional Testing Based on Valve Type :

Specific valve types may require additional testing, such as:
o Ball valves: Tight shut-off testing, flow characteristics testing.
o Gate valves: Wedge tightness testing, seating pressure testing.
o Globe valves: Shutoff characteristics testing, flow coefficient testing.
o Butterfly valves: Leakage testing at various angles, torque testing.
o Check valves: Cracking pressure testing, reverse flow testing.
o Safety relief valves: Pop pressure testing, reseat pressure testing.

5.1. TESTING PROCESS FOR THE PRV/PSV :

This method determine the seat tightness of the metal seated PSV, Including those of
conventional Bellows and pilot operated designs. The test medium of the determining the seat
tightness shall be the same as that used for determining the set pressure of the valve. For Dual
service valves, The test medium shall be same as the primary relieving medium. Test medium
shall be near to the ambient Temperature
.
5.1.1. PRESSURE TESTING WITH AIR :

Closed bonnet type

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Testing Apparatus: A Tube having 6mm ID with smooth and squarely cut end
Appropriately immersed 0.5 inches below the surface of water is used to determine
the seat tightness with air, for Closed bonnet type valves. This Apparatus is fixed to
the cover plate fixed at the outlet of the valve body.
Test Procedure: Before the leakage test, The set pressure shall be
demonstrated and all valve body joints and fittings should be ensured leak tight.,
Suitably covering the outlet of the valve.
Test pressure: For a valve whose set pressure is greater than the 3.5 kg/cm2 ,
the leakage rate shall be determined with the test pressure at the valve inlet held At
90% of the set pressure.
For a valve whose set pressure is 3.5 kg/cm2 or below , the
leakage rate shall be determined with the test pressure at the valve inlet held At 0.35
kg/cm2 less than the set pressure.
Acceptance Criteria: Before the bubble count the test pressure shall be
applied: 1 min for valve size < 2 NB 2 min for valve size 2.5 , 3 & 4inches 5 min for
valve size > 6 inches.
The valve shall be observed for leakage for at least 1 min. For a
valve with metal seat, The leakage rate shall be as per table below
For Soft seated valve there shall be no leakage.

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Figure 5-2 Testing with Air

Open bonnet type

Test procedure: For open bonnet type valve the bubbles check shall be
performed by filling the water 0.5 inches above the seating surface, Partially sealing
the outlet of the valve body.
Test pressure: Same as for closed bonnet valves
Acceptance Criteria: The valve shall be observed for leakage for at least 1
min. For a valve with metal seat , the leakage rate shall be 50% of Respective value
in table below. For soft seated valve there shall be no leakage.

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Figure 5-3 Testing with Water

5.1.2. PRESSURE TEST WITH THE WATER :

Test procedure: Before leakage test, the set pressure shall be demonstrated and
valve body outlet bowl shall be filled with water.
Test pressure: For a valve whose set pressure is Greater than 3.5 kg/cm2, The
leakage rate shall be determined with the test pressure at valve inlet held at 90% of the
set pressure.
For a valve whose set pressure is 3.5 kg/cm2 or below the leakage rate shall be

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determined with the test pressure at valve inlet held at 0.35 kg/cm2 less than the set
pressure.
Acceptance criteria: Test Pressure shall be applied when the outlet bowl get
stabilized with no further flow or dripping.
For metal Seated valve, Inlet size 1 inch NB or larger : 1cc per min
per inch of NB F or metal Seated valve, Inlet size smaller than 1 inch
: 1cc per minute

Set pressure Effective Orifice Size Effective Orifice Size larger

(At Ambient Temp.) 0.307”(F) And Smaller than 0.307”(F)

Kg/cm2
PSI Gauge Leakage rate bubbles per min. Leakage rate bubbles per min.
Gauge

15.1000 1.05-70.32 40 20

1500 105.48 60 30

2000 140.84 80 40

2500 175.80 100 50

3000 210.97 100 60

4000 261.29 100 80

5000 351.61 100 100

6000 421.94 100 100

1.Maximum Seat Leakage Rates For Metal-Seated PRVs

5.3. TESTING PROCESS FOR GATE VALVE :

1. Soap Test :
o Purpose: To visually detect minor leaks at the valve body, bonnet, and stem
connections.
o Procedure: Apply a soapy water solution to the suspected leak areas.
o Observe for bubble formation, indicating a leak.
o This test is primarily used as a preliminary check.

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2. Wedge Tightness Testing :

o Purpose: To assess the sealing performance of the gate valve's wedge against the
seats.
o Procedure: Close the gate valve completely.
o Apply a specified pressure to both sides of the valve.
o Monitor for leakage using pressure gauges or other leak detection methods. o
The leakage rate should be within acceptable limits as defined by industry
standards or specifications.

Figure 5-4 gate Valve Testing With water

3. Seating Pressure Testing :

o Purpose: To verify the pressure at which the gate valve's wedge seals against the
seats.
o Procedure: Close the gate valve completely.
o Gradually increase the pressure on one side of the valve while monitoring the
pressure on the other side.
o The seating pressure is the point at which no further leakage occurs.
o Compare the measured seating pressure to the specified value.

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5.4. TESTING PROCESS FOR CONTROL VALVE :

5.4.1. PRESSURE TESTING :
1. Hydrostatic Test:
o Fill the valve with water or a suitable hydraulic fluid.
o Apply hydrostatic pressure to a specified level, usually 1.5 times the maximum
allowable working pressure (MAWP).
o Hold the pressure for a specified duration to check for leaks and structural
integrity.
2. Pneumatic Test:
o Use compressed air to test the valve for leaks and seat tightness.
o Pressure levels are typically lower than hydrostatic tests.
o Suitable for valves handling gaseous media.
3. Leak Detection:
o Employ leak detection methods like bubble testing, dye penetrant, or
ultrasonic testing to identify any leakage points.
5.4.2. FUNCTIONAL TESTING :

o Flow Characteristics: Determine the valve's flow coefficient (Cv) and flow
characteristics curve to verify performance against specifications.
o Shutoff Capability: Evaluate the valve's ability to completely close and prevent fluid
flow.
o Cycle Testing: Open and close the valve multiple times to assess its responsiveness
and repeatability.
o Response Time: Measure the time taken for the valve to reach a desired position in
response to a control signal.
o Actuator Performance: Verify the actuator's operation, torque, speed, and travel
limits.
o Positioner Calibration: Check the accuracy and linearity of the positioner's output
signal.
o Control Signal Response: Evaluate the valve's response to various control signals to
assess its controllability.

5.5. BREATHER VALVE TESTING PROCESS :

Breather valves are critical components in many industrial applications, protecting equipment
from damage caused by pressure fluctuations. To ensure their proper functioning, rigorous
testing is essential.
Key Testing Parameters
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o Opening Pressure: This is the pressure at which the valve

begins to open, allowing air to enter or exit the system.
o Closing Pressure: This is the pressure at which the valve closes, preventing further
air ingress or egress.
o Flow Capacity: The valve must be able to handle the required airflow rate under both
pressure and vacuum conditions.
o Leakage: The valve should exhibit minimal leakage when closed.
o Durability: The valve should withstand environmental conditions and repeated cycles
without degradation.
Testing Methodology
1. Visual Inspection:
o Examine the valve for any physical damage, corrosion, or foreign matter.
o Verify that all components are present and securely assembled.
2. Pressure Testing:
o Positive Pressure:
o Apply increasing pressure to the valve inlet until it opens.
o Record the opening pressure.
o Verify that the valve fully opens and allows sufficient airflow.
3. Negative Pressure (Vacuum):
o Apply increasing vacuum to the valve inlet until it opens.
o Record the opening pressure.
o Verify that the valve fully opens and allows sufficient airflow.
4. Flow Capacity Testing:
o Measure the airflow rate through the valve at various pressure and vacuum
conditions.
o Compare the results to the valve's specified flow capacity.
5. Leakage Testing:
o Close the valve and apply a pressure or vacuum.
o Monitor for any pressure or vacuum loss over time.
o A leak test can be performed using a bubble solution or electronic leak
detectors.
6. Cycle Testing:
o Repeatedly open and close the valve under varying pressure and vacuum
conditions.
o Verify consistent performance and absence of any operational issues.
7. Environmental Testing (Optional):
o Subject the valve to extreme temperature, humidity, or other environmental
conditions as required by the application.

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Figure 5-5 Testing of Breather Valve

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CHAPTER 6: CONCLUSION
The summer internship at Flotec Techno smart (INDIA) Pvt. Ltd. Provided me with invaluable
hands-on experience in the field of mechanical engineering, particularly in valve servicing
and testing. The opportunity to apply theoretical knowledge to real-world scenarios allowed
me to bridge the gap between academic learning and practical application.

6.1. INTERNSHIP OBJECTIVES :

The primary objectives of this internship were to gain a deeper understanding of different
types of mechanical valves, learn the intricacies of valve servicing and testing, and develop
essential skills in using specialized tools and equipment. Though active participation in
various projects and tasks, I achieved these objectives, enriching my understanding of the
mechanical engineering field.

6.2. INTERNSHIP ACTIVITIES :

During the internship, I was engaged in a wide range of activities, including the disassembly,
inspection, and reassembly of valves, conducting various tests to ensure quality and safety,
and working closely with experienced professionals who provide valuable mentorship. These
activities not only enhanced my problem-solving abilities and attention to detail.

6.3. KEY LEARNINGS :

This internship has significantly contributed to my professional growth. I have gained a
comprehensive understanding of the operational procedures and safety standards essential in
valve servicing. I have also developed a keen insight into the importance of quality control
and role of precision in mechanical engineering tasks. Additionally, working in a team
environment has strengthened my communication and collaboration skills, which are critical
in a professional setting.

6.4. CONCLUSION :
The internship at Flotec Techno smart Pvt. Ltd. was a transformative experience that equipped
me with practical skills and knowledge crucial for my future career in mechanical
engineering. The exposure to industry practice, coupled with the guidance from seasoned
professional, has prepared me to take on more complex challenges in the field. I am confident
that the lessons learned during this internship will serves as a strong foundation as I pursue
my career in mechanical engineering. And I am grateful for the opportunity to contribute to
and learn from such a dynamic and innovative company.

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REFERENCES

1. cncontrolvalve.com/how-is-the-pressure-safety-valvepsv-designed/
2. as-schneider.blog/2022/08/10/types-of-valves-used-inpiping-and-
how-to-classify-them/
3. nirmal.co.in/
4. flotecindia.com/
5. hqts.com/valve-testing-standards/
6. protectoseal.com/the-essential-guide-to-breathervalves/
7. qrcvalves.com/api-6d-valves-types-vs-api-598/

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