I am Amandeep Singh reg no.

100221129237
a student of Mechanical Engg. From CT
Institute The sense of veneration and gratitude
through words would hardly suffice my feeling
of respect for my revered major advisor Dr.G.D
Sahni (H.O.D of design and development
department for LEADER VALVE) for planning
the program of study. His intellectual
stimulation, valued guidance, unfailing courtesy,
judicial constructive and untiring efficient efforts
have helped towards the successful completion
of the endeavor. Also, I express my sincere
thanks to the entire engineering, administrative
and work staff of LEADER VALVES Ltd. For
helping me throughout my six months training
and project
 INDEX 1.Objective of training 2.Introduction
3.History 4.Company profile 5.Objective of
Leader Valve Limited 6.List of valves
manufactured 7.Description of valves 8.Unit of
industry 9.Ferrous foundry 10.Non ferrous
foundry 11.Materials 12.Valves 13.Various
sections

Introduction to LEADER VALVES Pvt Ltd.

 Leader valve ltd is a leading manufacturing of valves and boiler mounting
in India producing more than 800000 valves annually. The company was
set up about 6 decades ago when India was on the threshold of industrial
revolution and there were no good valve manufacturing in the country. It
has over years built up an excellent track record by following the POLICY
OF CONSUMER SATISFACTION. It has obtained ISO: 9001-2008
certification from LRQA India. Its Ferrous and non ferrous foundries are
PED certified by LRQA India and AD 2000 Marketblatt WO certified by TUV
India. The foundries are also adjudged as well know foundries under Indian
Boiler Regulation 4c(2) of central boiler board , govt. of India The company
has API Spec .Q1 and API 6D monogram for oil petrol pipelines. API
certification No. 6D-0346 API certification No. 600-0018 HISTORY It all
began in the year 1945, when a small proprietary firm named SHAKTI
ENGINEERING was started by entrepreneur , now Late Mr. P.N.Beri. It
was a humble start with a workforce of 6 to 7 people. The original plant was
located on mandi road near Laxmi cinema in jalandhar. The first sales were
made to Gobind ram, chaura bazaar, Delhi. The company opened shop as
partnership with meager resources and a limited manpower of less than 20.
As the sales pitch kept on the rise it was decided to shift the plant in the
year 1950 on Vishwakarma Puja day to the premises on Hoshiarpur Road.
The land was taken on lease from farmers and construction made on it as a
partnership firm and the name was changed to LEADER ENGINEERING
WORKS. Smt. Sarla Beri and her son now occupy this building. Due to
further rise in the sales and future requirement of valves from both within
country and abroad, the chief as Sh. P.N.Beri was then caller by all his
work force, lovingly took major task of moving the entire unit. This is
located in Industrial area, which took place in the year 1960. And as the
years went by, with the perseverance and dedication of the people, the
fledgling company is now proper valve industry with over 1100 dedicated
employees with an annual turnover of Rs.880millions for the year 2011-12.
From the pioneering days of the 40s, when leader introduced gunmetal
gates, globe and check valves, for domestic use, it has since then
introduced largest variety of valves ever to be produced under one roof
making over 1000000 quality valves annually. In this innumerable variety,
they manufacture valves of copper based alloys, cast iron, carbon steel,
cast stainless steel, ductile iron, malleable, bronze, alloy steel, forged
carbon steel and investment carbon steel in size ranging from to 24.
Leader is equipped with its in house Ferrous and Non-ferrous foundries
division, ensuring that right from the beginning we do thing right. Strict
quality control standards and maintained by using the latest in precision
testing facilities, to make sure that whatever goes into making one of our
valves is of the most superior quality. Leader achieved another milestone
when its quality management system was found conforming to ISO-
9001:94 by LLOYD S REGISTER QUALITY ASSURANCE. And now its
working on the system ISO-9001:2008 certified by LRQA. The company
over the year has developed numerous special purpose valves of their
values customers which includes, to name a few ship builders, Steel plant,
Textile industries, Sugar industries, India navy Petrochemical companies,
Boiler mountings, Fertilizers plant, Thermal, Hydro and Nuclear power plant
and various other industries. The aim of Leader Valve ltd is to achieve a
100 core target at the turn of the century and this is their biggest
motivation. The M.D says We are in the midst of vast expansion and
modernizing plans. The year 1997 coaster ride for Indian economically,
recession was a world the bounced on the forefront of our stagnant
industrial setup Leader valves too has suffered but managed to pull clear
without being severely affected by the downwind market scenario. This
itself speaks volumes for the goodwill and faith of its customers in the
industry which has helped it to forge ahead oblivious to stumbling blocks.
COMPANY PROFILE ADDRESS OF THE COMPANY:- Leader valves
limited (Property of Leader engineering work) S-3, S-4, Industrial area.
Jalandhar-144004 PUNJAB Phone no. :-+91-181-2290412, 2290663,
2290373, 5084444. Fax no. :- +91-181-2290894 Nature of the company:-
Limited Co. P.S.T/C.S.T. Regd No. :- 27953010 Central excise no :- J-
1/CH-84/46/9 Account No.:- AAACL2362H YEAR OF ESTABLISHMENT:-
1950 AREA OF FACTORY:- TOTAL AREA:-53576 Sq Mt. COVERED
AREA:- 20290 Sq Mt. ELECTRICTITY LOAD:- Sanctioned load-4650KW .
The company also has stand by generator of 2500KVs for the entire
foundry and machine shops electricity department. Employee Strength:-
The company has over 1100 dedicated and motivated people who are
working round the clock to produce best quality valves for the industry.
Annual turnover:- Presently the plant is working at 80% of its installed
capacity due to recent modernization and expansion. Turn over during
2011-12:-Rs 880millions Turn over during 2010-11:-Rs 798millions Turn
over during 2009-10:-Rs 719millions Engineering staff:-85 Departmental
breakup as follows:- MARKETING AND SALES DESIGN AND
DEVELOPMENT PRODUCTION PLANNING MATERIAL MANAGEMENT
QUALITY ASSURANCE CALIBRATION FERROUS FOUNDRY
SERVICING ELECTRICAL MAINTENANCE MECHANICAL
MAINTENANCE HEAT TREATMENT AND WELDING WORK FORCE:-
Total strength :- 1012 Skilled-: 700 Semi skilled-:156 Unskilled-:156
CASTING CAPACITY:- The castings are produced in the foundries which
are equipped with the latest equipment with latest equipments and modern
laboratories. The non-ferrous foundry is having two induction furnaces of
1000Kg and 750Kg capacity respectively and they can melt around 500
tons copper alloys per month per shift. The non ferrous castings are
produced by shell molding process. The ferrous foundries is equipped with
one ton induction furnace with 2 crucibles and ARPA1300 molding
machines along with mechanized sand plant. With the ongoing
modernization program, the output of the ferrous foundry will increase to
300 tons per annum of radiographic quality steel and alloy steel castings.
FORGED SHOP:- The forging shop is equipped with ROVETTA ISGEC
350 Ton capacity forging press for making brass forging and 300 ton
extrusion pres besides other small capacity hammers and induction
furnaces. These are also available in 1000kg. Friction Drop forging hammer
for producing forging valve up to 50NB. WORKSHOP:- Workshop have
more than 400 machines including SPM s and CNC machines capable of
carrying out all types of precise machines operations. The company has
installed state of the art CNC machines such as JUARUSTI CNC horizontal
machines center for machining gate, globe and check valves up to 36 inch,
PRAGA MITSHUBISHI CNC horizontal machining center Model MPA-
H50A for machining valves up to 14 inch, and CNC SPM to machine
butterfly valves. Recently the company has installed two CNC HESSAP
make vertical turning machine and MAXMULLER make horizontal turning
machine. QUALITY ASSURANCE:- The company maintain strict control on
quality in all stages of production right from raw material to shipment. The
company has in house quality control lab that is equipped with UTM,
SPECTRO analyzer, Impact testing machines, and hardness testing
machine. The company has an all NDT equipment such as Radiography,
UT, MPI and DP. Added to this qualified level 2 professional who carry out
NDT operations. We have facilities for radiography of casting, Die
penetrate and magnetic particle inspection of material, NDT, In house
spectrometer for physical analyzer and specialized tests are furnished on
demand. Companies 10Q.A personnel are trained and qualified in
accordance to SNT-TC1A for carrying out non-destructive examination of
job. Company has its own standard room for calibration of measuring
instruments, gauges and temperature recorders etc. CONTINUAL
IMPROVEMENT PROGRAMME THROUGH R&D AND HRD LEADER
being an ISO 9001 company, all its designs/products are validated for the
specified service conditions by using in-house testing facilities or by using
facilities at recognized test house. The product improvements are done
under the supervision of highly experienced and qualified engineers.
LEADER is committed to its employee development program by imparting
technical training on a regular basis to ensure staff is capable of rendering
best possible support to our customers at any time. Companies 6 officials
have successfully completed the course of Lead Auditor of quality
management system of ISO 9000. The company has successfully tested its
pull test as per API590. Product Range:- The company is able to offer
complete range of valves as well as being able to develop special valve for
critical applications. The product range includes:- Ferrous/Non-ferrous
Gate/Sluice/Globe/Check/Reflux Valves/Butterfly Valve/Ball Plug valve and
Expansion joints etc, from a 6mm in pressure rating class-124 to 2500. The
company also manufactures Fire Safe Gate, Globe, Check and Ball valves.
Boiler mountings i.e. Pilot operated pressure reducing valves, safety
single, Double Post, Steam Stop valve, Injectors, Steam traps, Relief
valves, Parallel slide valves, Non return valves etc in ferrous/non-ferrous
materials form 15mm etc. The company specializes in actuated Gate,
Globe, Butterfly, and Ball valves. Marine valves Special purpose valves to
meet specific requirements of the customer. Special Testing Facilities
Vacuum testing facilities Helium testing facilities Cryogenic test rig and
testing facilities Fire safe test rig and testing facilities Endurance testing
Pull test as per API591 Companies Proud Patronage National:-
Engineering Indian Limited(EIL) Indian Oil Corporation Ltd.(IOCL) Indian
Petrochemical Ltd Bongaigaon Refinery and Petrochemical Ltd. National
Thermal Power Corporation Ltd. Bharat heavy electrical Ltd. Garden
Reach Shipbuilder and engineers Ltd. Magagon Dack Ltd. Fert. Corpn. Of
India Ltd. National fertilizer Ltd. Rashtriya Chem. And Fert. Ltd.
Hindustan Petrolium corporation Ltd. Technical Development Committee
LLOYD s register industrial services(India) Ltd. Asia Brown Boveri
J.N.Marshall Ltd. Gas authority of India Ltd. Bharat heavy plate and
vessel Ltd. INTERNATIONAL:- Malbranque, France Mikon Int, USA
A1 Bassam UAE Kuwait National Petroleum Co. Saudi
transformers , Dammam T&I Singapore G.E International U.K
Inter Power Ltd, Malta Ansaldo Engeria s.p.a, Italy Management
Information System:- Leader is implementing integrated data base on line
management information system in order to cater long term information
requirements of various functions of the organization MRP-II is under
implementation. Management:- The company is managed by an efficient
board of directors and well qualified professionals. AIM:- The aim of the
company is to give a long term commitment to their customers, working in
close co-operation, ensuring total quality and reliability through continuous
product development/improvement.

OBJECTIVE OF LEADER VALVE LIMITED DESIGN

IMPROVEMENT:- The emphasis is on improved
safety, easy handling, high corrosion resistance and
longer life of valves and boiler mountings.
TECHNOLOGY:- Keeping pace with the latest
technological developments in manufacturing of
valves. PRODUCTIVITY:- Improvement in
productivity vis--vis the existing valves. QUALITY:-
Maintaining workmanship of higher international
standards.

List of valves manufacture by Leader Valves

Limited BALL VALVE AIR RELEASE VALVE
DIAPHAGRAM VALVE BLOW OFF VALVE
BUTTERFLY VALVE PARALLEL SLIDE
VALVE WAFER TYPE CHECK VALVE
FLOAT VALVE SAFETY VALVE FOOT
VALVE GATE VALVE GLANDLESSS
PISTON VALVE GLOBE VALVE GLOBE
STEAM STOP AND NON RETURN VALVE
RELIEF VALVES PRESSURE REDUCING
VALVE PLUG VALVE ON RETURN VALVE
Bib Cock

Material Used:- CAST IRON GUN METAL BRASS BRONZE STEEL BRASS Brass is an alloy of copper and zinc, the proportions
of zinc and copper can be varied to create a range of brasses with varying properties. By comparison, bronze is principally an alloy of copper and tin.
Bronze does not necessarily contain tin, and a variety of alloys of copper, including alloys with arsenic, phosphorus, aluminum, manganese, and
silicon, are commonly termed "bronze". Brass is a substitute alloy for copper. It is used for decoration for its bright gold-like appearance; for
applications where low friction is required such as locks, gears, bearings, doorknobs, ammunition casings and valves; for plumbing and electrical
applications; and extensively in musical instruments such as horns and bells for its acoustic properties. Brass has higher malleability than bronze or
zinc. The relatively low melting point of brass (900 to 940 C, 1652 to 1724 F, depending on composition) and its flow characteristics make it a
relatively easy material to cast. By varying the proportions of copper and zinc, the properties of the brass can be changed, allowing hard and soft
brasses. Today almost 90% of all brass alloys are recycled because brass is not ferromagnetic, it can be separated from ferrous scrap by passing the
scrap near a powerful magnet. Brass scrap is collected and transported to the foundry where it is melted and recast into billets. Billets are heated and
extruded into the desired form and size. To enhance the machinability of brass, lead is often added in concentrations of around 2%. Since lead has a
lower melting point than the other constituents of the brass, it tends to migrate towards the grain boundaries in the form of globules as it cools from
casting. The pattern the globules form on the surface of the brass increases the available lead surface area which in turn affects the degree of
leaching. In addition, cutting operations can smear the lead globules over the surface. These effects can lead to significant lead leaching from brasses
of comparatively low lead content. Silicon is an alternative to lead, however when silicon is used in a brass alloy, the scrap must never be mixed with
leaded brass scrap because of contamination and safety problems. Season cracking:- Brass is susceptible to stress corrosion cracking, especially from
ammonia or substances containing or releasing ammonia. The problem is sometimes known as season cracking after it was first discovered in brass
cartridge cases used for rifle ammunition during the 1920s in the Indian Army. The problem was caused by high residual stresses from cold forming of
the cases during manufacture, together with chemical attack from traces of ammonia in the atmosphere. The cartridges were stored in stables and the
ammonia concentration rose during the hot summer months, thus initiating brittle cracks. The problem was resolved by annealing the cases, and
storing the cartridges elsewhere.
Objective of Training The main objective of the
training was to get a first hand technical and
practical knowledge about the industry. The
main thinking was that the students would
become familiar with the industrial problems, its
working , so that they can take up future
challenges when they turn up in an industry
with good confidence