The document provides a summary of Pragyaditya Das's two-week summer training at Flowserve India Controls in Bangalore. It describes the various departments at Flowserve such as Human Resources, Administration, IT, Sales, Finance, Contracts, Design, Quality Control, and Special Projects. It explains the roles and responsibilities of each department. The training covered the history and acquisitions of Flowserve, industries it serves, and an overview of the different processes involved across departments from order receipt to manufacturing and delivery.

1. FLOWSERVE INDIA CONTROLS, BANGALORE
REPORT ON SUMMER TRAINING
Pragyaditya Das
Department of Instrumentation and Control.
National Institute Of Technology, Trichy
Thisis a reporton the two-weeksummertrainingatFlowserve IndiaControls,Bangalore.Contacts:
pragyaditya.das94@gmail.com;+91 8754218356.

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Contents
1.Introduction.
1.a. History.
1.b. Acquisitions.
1.c. Industries Served.
2. Various Departments.
2.a. Human Resources.
2.b. Administration.
2.c. Information Technology.
2.d. Sales.
2.e. Finance.
2.f. Contracts.
2.g. Design.
2.h. Applications and Global Projects.
2.i. Quality Control and ISO.
2.j. Special Projects
2.k. Field Service.
2.l. Production.
2.m. CIP & EHS.
2.n. Supply Chain.
2.o. Project Management.
3. Conclusion.

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1.INTRODUCTION
Flowserve is a leading manufacturer and aftermarket service provider of
comprehensive flow management products and solutions. The products manufactured by
Flowserve help in moving, controlling and protecting the flow of materials in
critical industries around the world.
The Flowserve Corporation is an American Multinational Corporation and one of
the prime and largest suppliers of Industrial and Environmental machinery such as
Pumps, Valves, End Face Mechanical Seals, Automation, and Services to the Power, Oil
and Gas, Chemical and other process industries.
The Flowserve Corporation is headquartered at Irving, Texas, it houses to ov er
15,000 employees in 51 countries.
It sells products, provides post-market services, and offers to engineering
and construction firms, original equipment manufacturers, distributors and end users.
The Flowserve branded name originated in 1997 with the merger of BW/IP and
Durco International.
a.HISTORY :
Flowserve Heritage dates back to the 1970 founding of Simpson & Thompson by
Thomas Simpson, later to become Worthington Simpson Pumps, one of the companies that
became part of BW/IP. The company was created in 1997 with the merger of two fluid
motion and Control companies – BW/IP and Durco International.
b.ACQUISITIONS:
Acquisitions include HydroTechnik Olomouc in 2006, Sealing Systems in 2007,
Calder Ag in 2009, and Valbart Srl in 2010. In October 2011 Flowserve acquired
Lawrence Pumps Inc. Also in March 2013, it acquired one plant from L&T Valves (Aduco
India Limited) situated in Maraimalainagar, Tamil Nadu.
c.INDUSTRIES SERVED:
i. Oil and Gas (Production, Refining, Pipeline, Gas Processing).
ii. Power Generation (Nuclear, Combine Cycle, Boiler, Water
Energy).
iii. Chemical Processing (Acid Transfer, Caustic and Chlor-Alkali,
Polymers, Slurry Processing, Voltaic and Organic Operation,
Auxiliary).

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iv. Water Resources (Supply, Distribution, Treatment, Flood
control, Irrigation).
v. General Industries (Mining, Primary Metals, Pulp, Paper).
Sources: a. Wikipedia.org/wiki/Flowserve.
b. www.flowserve.com

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2.VARIOUS DEPARTMENTS
Various departments work for the smooth functioning of the company. All of them tap
into the Work Flow of the company at crucial stages and play their respective roles.
Here, I present the brief overview of the departments, along with the nam es of the
respective Instructors.
2. a. Human Resources:
Instructor: Mr. Anil Fernandes.
Date: 11/05/2015.
This was the first day of my training, in this module Mr. Anil explained me
about the various aspects of Human Resources department. Moreover, he also gave me
the introduction about the Flowserve, India.
Here are the various salient points mentioned by him about the Flowserve India
Controls:
Flowserve Organization is mainly divided into three parts:
a. FCD (Flowserve Control Division):
- Manufacturing plant at Whitefield, Bangalore.
- It is an EOU (Export Oriented Unit). 90 % of the
manufactured items are Exported; other 10 % is sold in
the Local Market.
b. GTEC (Global Technology and Engineering Center) :
- This group works in association with Order Engineering,
Application and Design Engineering and BOM (Bill Of
Materials) Team.
- They are responsible for product development and
Research.
c. FSG (Flowserve Solutions Group) :
- This division deals with pumps.
- Manufacturing plant at Coimbatore, Chennai.
Here are the various tasks taken care by the Human Resources team at
Flowserve:
WELFARE MEASURES:
Mediclaim Insurance Coverage:

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i. Mediclaim Insurance coverage for self plus 3
dependants.
ii. Dependant Definition: Spouse, Two Children,
Dependant Parent with first preference to
Spouse and Children.
iii. Coverage upto : Rs. 450,000/-.
iv. 24 Hour Accident Insurance Coverage. (2 Times
the base pay).
OTHER BENEFITS:
i. Superannuation:
a. Retirement Benefit: 10 % of basic salary
per month.
b. The Funds are managed by LIC.
c. For all these services, the employee must
provide a minimum of 3 years of service.
ii. Statutory Benefits:
a. Provident Fund: 12 % of Basic Salary is
collected every month and the sum total is
given at the time of retirement.
b. Gratuity: On completing 5 years of
Service, the employee is given some amount
money.
c. Employees deposit linked Insurance Scheme.
-The Company maintains its Quality and its mark at the Global Platform using 6-Cs.
They are as follows:
Competence.
Collaboration.
Commitment.
Creativity.
Character.
Confidence.

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2. b. Administration:
Instructor: Mr. Raghavendra.
Date: 18/05/2015.
In this module, Mr. Raghavendra briefed me about the various functions of the
Administration Department in the day-to-day functioning of the company.
The salient features of this module are as follows:
a. They do not play any role in the Sales.
b. The flow is as follows :
Legal  Welfare  Administration.
c. This department takes care that there is no Violation of rules in
the Plant.
d. This department takes care of the Health Centre.
The Health Care Centre is set up as per the Factories Act, 1948.
Whenever there is strength of 500 or more, the company must set
up a primary Health Care Centre.
e. This department takes care of the various Housekeeping tasks like,
cleanliness, availability of basic amenities and Proper execution
Safety rules by the Employees, when in the Plant.
f. This Department also does the PMS (Performance Management Program)
and Grades the Employees accordingly.

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2. c. Information Technology:
Instructor: Mr. Pavithran Ayyala.
Date: 12/05/2015.
In this module, Mr. Ayyala, briefed me about the IT department of Flowserve.
The various salient points are as follows:
a. The company does its various works, such as Valve Sizing, Creating
the BOM etc. on a Oracle based ERP.
b. At one time, Flowserve had more than 1000 ERPs functioning in it.
Now it has come down to a small number, with ORACLE ERP as a
majority.
c. This Department works on bringing uniformity to the company. To
create one, unified and mass-accessible information centre.
d. The company uses an MPLS (Multiprotocol Label Switching) based
Business Intelligence System, which puts all the data from the
various departments into One, Oragnised Place in a more Efficient,
Smart and Readable manner.
e. The IT department is not involved in any Development works, however,
they are into maintenance and service.
f. The development work is Outsourced from Companies like TCS,
Capgemini etc.
g. The company also has reputed antivirus and various measures it takes
to keep Black-Hat Hackers away from Hampering the company.
h. The Data center of Flowserve is based at UK.
i. All processes entered into the Oracle ERP system is readily
available for viewing in all the Flowserve Centers all over the
world.

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2. d. Sales:
Instructor: Mr. Bobby Poulose.
Date: 12/05/2015.
In this module, Mr. Bobby Poulose, explained me about the various aspects of
Sales Department. The salient points mentioned during this encounter are as follows:
a. This department works in two parts:
1. Inside Sales (ISP).
2. Outside Sales (OSP).
b. They work actively in the field of Marketing.
c. When they get an Order from the customer, their job is to precisely
understand the customer needs and generate a booking, which are both
costs efficient and non-compromising with the Quality of the
manufacturing goods.
d. The basic flow of this department is as follows:
Order  Engineering  Create Booking  Marketing.
e. This department also takes care that the company has a good relation
with the customers.
f. This department makes sure that the company is at profit, however
without compromising with the Quality of the product manufactured.
g. This department is responsible for generating the Feasible the Price
of the Products. The price must compete with the other vendors in
the market too.

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2. e. Finance:
Instructor: Mr. Sethu.
Date: 23/05/2015.
In this module, Mr. Sethu, explained me about the various aspects of Finance
Department. The salient points mentioned during this encounter are as follows:
a. Mr. Sethu explained me how the Finance department is related to
almost all the departments of the company. Each department in the
company, directly or indirectly, works with Finance Department.
b. Finance comes into the picture right from the Receiving the Contract
until the time the customer makes the Payment to the company.
c. The Finance Department also takes care of all the other expenses,
like, External Payments, Payment to Transporters, Payment to
Security, Payment to Medical Professionals, and Payment for the
other amenities.
d. This department also takes care of the Legal part associated with
business.
e. The company does not have to pay any Excise duty, because it is a
100 % EOU (Export Oriented Unit). However, the company the companies
they are dealing with must have CT-3 registrations.
f. For sales inside Karnataka, they pay 14 % VAT; and for sales outside
Karnataka they pay 2 % from Form C.
g. Major Taxes that the company pays are Service tax, Sales Tax and
Income Tax.
h. This department also takes care of the Audit. The Audit is done by a
firm named PWC (Price Waterhouse and Coopers).
i. During the Annual Report making the department functions in the
following way :
Check Reports  Cross-Verify  Make Balance Sheet Calculate Profit/Loss.

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2. f. Contracts:
Instructor: Mr. Rejith.
Date: 11/05/2015.
Mr. Rejith, in this module, explained me how the Contracts team works. The
salient features of this team are as follows:
a. This department looks after the Marketting division of the Company.
b. This department appears when the customer places the enquiry.
c. After the enquiry is received, this department coordinates with the
various departments and checks if the company can deliver what the
company wants.
d. Later, after the enquiry is received, accepted and finalized; they
enter the details into the Oracle ERP.
e. This department plays a key role in the making of BOM (Bill Of
Materials). They take care of the entire contractual deals that are
made between other companies and Flowserve.
f. This department also works along with the Engineering teams on the
Development of MRP (Material Resource Planning).

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2. g. Design:
Instructor: Mr.Srinivasa.
Date: 15/05/2015.
In this module, Mr. Srinivasa, explained me how the design team works. How
the required product is designed and made available to the customer at the earliest.
The salient point of this module are as follows:
a. The work of the design team starts when the contracts team gets the
order.
b. After the order is received, the design team checks if the customer
requirement matches with any Existing valve, if it does not exist,
then a design a new one.
c. The new design is sent to the BOM team, which decides the materials
required.
d. To identify the parts of the valve, this team uses software called
EXTRANET.
e. The R&D team and the Quality Assurance team test the new design. If
it passes all the tests, it is sent for manufacturing, if not, it is
sent back to the Design Team for reviewing.
f. After the design is finalized, the Design team makes a DRD (Drawing
Release Document) and a GAD (General Assembly Drawing).
g. These two documents contain all minutes of the new design, which
help the Production team to manufacture it without any problem.

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2. h. Application and Global Projects :
Instructor: Mr.Sridhar.
Date: 13/05/2015.
In this module, Mr. Sridhar explained me the various Flow Control Operations
the department does. The various points of this training are as follows:
a. In the beginning of this training, he listed some of the types of
valves the company manufactures, namely, Ball Valve, Sliding Ball
Valve, Globe Valve, Butterfly Valve etc.
b. After the Design, team checks the availability of the valve, and
based on this, the design team make new designs.
c. The new designs are sent to the Application Team for generating a
Valve Sample File. This file is again generated using a VALVE
ENGINEERING SOFTWARE, called PERFORMANCE.
d. The materials used in the Valve are based on a particular standard,
called the ASTM (American Standard for Testing and Materials). In
most cases, the customer asks for this, however, in some cases the
customer might also ask for some other standards.
e. The major materials used are Carbon-steel, Stelite-6, Monel, Inconel
etc.
f. The valves should be certified to work in Hazardous locations.
g. There are various hazardous location certifications, some of them
are ATEX, IECEx, CSA, FM etc.
h. The cavitations and valve sizing formulae can be obtained from IEC
60534 – 4.
i. ISA-75.01.01 is the document that provides all the necessary flow
equations used in the sizing of valves.
j. There are various standards for noise consideration, and these
standards are different for Gas and Liquid systems.
k. This team provides support to all global flowserve facilities.

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2. i. Quality Control and ISO :
Instructor: Mr.Vivek.
Date: 15/05/2015.
In this module, Mr. Vivek, explained me how the QC team supports the Designs
team and the Applications team. The main points of this training are as follows:
a. This department reviews the project documentation and provides
support to the application team.
b. They provide the details about the test plans and test procedures to
the project management for customer approval.
c. Then the requirements of the QA testing is sent to the BOM.
d. It is then sent for Customer and Supplier Approval.
e. They also check the site inspection raw materials.
f. They inspect the machining parts inspections, dimensionality check
and NDT.
g. They also do the PMI (Positive Metal Identification) test.
h. Sometimes the customer want to witness or review the tests, in such
cases, they department does things that are feasible to the company.
i. They also do the final inspection as coordinated by the Customer.
j. The finally make the MDR (Material Data Record). This contains
approved drawings, test documents, and operating manual and
certifications.
k. For tackling failures, they obtain a 8 Discipline approach, namely,
Nature of Complaint, Containment Action, Root cause analysis,
Corrective Action, Review Process planning documents, Review
operation documents, provide evidence, and show Preventive actions.

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2. j. Special Projects:
Instructor: Mr. Ramesh Hariharan.
Date: 14/05/2015.
In this module, Mr. Ramesh, explained me about the various mechanical and
electronic components involved in the valve mechanism.
He gave me a task of properly understanding what a control valve is. Some very
basic definitions are as follows:
a. Control Valve: Control valves are valves used to control conditions
such as flow, pressure, temperature, and liquid level by fully or
partially opening or closing in response to signals received from
controllers that compare a “setpoint” to a “process
variable” whose value is provided by sensors that monitor changes in
such conditions. Control Valve is also termed
as the Final Control Element.
b. HART: The HART Communications Protocol (Highway Addressable Remote
Transducer Protocol) is an early implementation of Fieldbus, a
digital industrial automation protocol. Its most notable advanta ge is
that it can communicate over legacy 4-20 mA analog instrumentation
wiring, sharing the pair of wires used by the older system.
(SOURCE : WIKIPEDIA)
The salient features of this training work are as follows:
a. There are mainly two kinds of control valves, Rotary and Linear.
b. They mostly use the two wire transmitters.
c. He showed me the working of a Logix Digital Positioner too.
He then took me to the manufacturing unit to show me the working of a valve.
He also showed me a valve connected to a mini-DCS, which was used for simulation.

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2. k. Field Service:
Instructor: Mr. Nagendran.
Date: 18/05/2015.
In this module, Mr. Nagendran explained me how the field service of the
company works. The main points are as follows:
a. This department works hand in hand with the Contracts team.
b. This department takes complaints from the customer and makes the
other departments aware of it.
c. They check for any mistakes and miscommunications.
d. After they find the error, they rework on the problem.
e. The above measures are taken if the product is under warranty. If the
product is not under warranty, the company charges for its services.
f. This department advises the customers to periodically change the soft
parts of the valves to increase the operational life of the valve.

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2. l. Production:
Instructor: Mr. Dinesh.
Date: 22/05/2015.
In this module, I was trained about the various aspects of Production in the
company. The important points are as follows:
a. This department works as per the monthly planner, prepared by the
Planning department.
b. They schedule the manufacturing of the valves.
c. They issue the Job Card and Material Listing.
d. The Job Card contains all details about the Routing, as per which the
machining pattern is decided.
e. There are various In-house machining centers. They are:
CNCs (Computerised Numerical Control), Horizontal Turning
Centres, Conventional Turning Machines, and Various Types of
Welding Facilities.
f. Production Plans the activities carried out by the Shop Engineering.
g. After the Production is done, the product is dispatched if it is a
parts order, or it is sent to the assembly if it is a valve order.
h. After the final inspection is done, painting is done.
i. After this, product is packed and dispatched.
j. At each step of the production, QA will be involved.

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2. m. CIP & EHS:
Instructor: Mr.Suryaprakash.
Date: 22/05/2015.
CIP expands to Continuous Improvement Program.
EHS expands to Environmental and Health Safety.
In this module, Mr. Surya, explained me what the company to does to work
efficiently and keep its employees safe. The main points are as follows:
a. The main roles of this department are Costing, Estimation,
Definition of Process, Routing, Test Identification and
Manufacturing Engineering.
b. In CIP, they mainly focus on LEAN Management and Six Sigma.
In these, the basic aim is to reduce waste. Be it wastage of human
resources or wastage of materials.
c. They minimize any over production, Inventory, Defects, Unnecessary
Transportation, Product Delay and Under Utilisation of Skills.
d. In EHS, they mainly focus on the keeping the emissions to the
minimum and keeping the work space safe.
e. They minimize the hazards by identifying and analyzing them.
f. They also provide various PPE (Personal Protection Equipment) for
the safety of the employees in shops.
g. They also use various Administrative Controls to keep the work space
safe.
h. Various engineering controls are also taken to keep the work space
safe.

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2. n. Supply Chain:
Instructor: Mr.Nagaraj.
Date: 24/05/2015.
In this module, I learnt how the Supply chain team of the Company works. This
department works with the planning team. The main points of this training are as
follows:
a. They separate the valve and parts ordering from the BOM.
b. They do the scheduling along with the planning department.
c. They communicate with the Buyers and get a date fixed for dispatch.
d. They schedule and sort the raw materials and Finished goods in their
respective stores.
e. They then create the KIT PICK list which is used by the Stores
department for getting the parts used for Valve manufacturing.
f. The supplier of raw materials are selected either by a Supplier
Evaluation Committee, or approved by Principal, or ISO Approval, or
Customer Approval.

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2. o. Project Management:
Instructor: Mr.Arun Venugopal.
Date: 19/05/2015.
In this module, Mr. Arun, explained me about how a particular project is
managed. The various problems they face and how they solve it. The salient features
are as follows:
a. They receive the valve order folder.
b. They review the GAD, Numeric and Electronic Schematic, Check the 4
Digit QA code.
c. They also review if the process is running as per the dates of
shipment.
d. This department does the management and the engineering works too.
e. This department gets involved in the Engineering work to do the post-
order changes.
f. This department also takes care of the Price Implications due to the
Post Order Changes.
g. They are not coordinated with the Engineering teams.

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1.CONCLUSION:
The training was for two weeks. It got over on 22/052015. I am very thankful
to Mr. Thiru and his colleagues of the HR department for assisting me and making me
feel at home in the New and Alien Environment.
It was a great learning experience. It was a praiseworthy experience to see
such a big industry work so smoothly without any chaos.
The details provided in the report are correct, to the best of my knowledge.
Lastly, I would like to thank all the instructors who found time from their
busy schedule and gave me the bits of knowledge.
Pragyaditya Das.
Department of Instrumentation and Control
National Institute Of Technology,Trichy.
Zircon A63, 620015.
pragyaditya.das94@gmail.com.
+918754218356