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Transcript of BFL Report
Internship Report Bindagi, Anuj Boving Fouress Ltd. July 31, 2014
Page | 1
INTRODUCTION
This is a report of my internship at Boving Fouress Ltd. In my training period, I have been
through various and have gathered basic information from each of these. This report is my
attempt at presenting the knowledge garnered during this period.
bfl- Boving Fouress Ltd.
BFL offers total solutions for Small Hydro Electric Power Stations (up to 25 MW Single
unit) starting right from the selection of machines to commissioning of the power plant, and is
fully geared to execute projects on ‘Water to Wire’ basis.
Objective: Powering the world today for a better tomorrow
BFL’s Global presence
India
North America
Latin America
Turkey
South Africa
Zimbabwe
Sri Lanka
Indonesia
Malaysia
Vietnam
Philippines
Thailand
VISION
To become the world’s largest Small Hydro Turbine manufacturer in “water to wire” Electrical
& Mechanical equipment by continually providing competitive solutions to the market.
Internship Report Bindagi, Anuj Boving Fouress Ltd. July 31, 2014
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SMALL HYDRO POWER
Small hydro power is the ability to generate power from potential energy of water flow at
a height to kinetic energy which rotates the turbine. This rotation of turbine shaft is coupled to a
generator converting mechanical energy to electrical energy.
Components of Small Hydro Power
1. Civil structures
Intake channel
Desilting tank: Debris in the water is allowed to settle down and also filters the
water through the trash racks.
Forebay tank
Tailrace
Intake gates/valves
2. Hydro-mechanical structures
Penstock
Surge shaft
3. Electro-mechanical structure
4. Transmission lines
HYDRO POWER PLANT
Hydropower plants harness water's energy and use simple mechanics to convert that
energy into electricity. Hydropower plants are based on a rather simple concept -- water flowing
through a dam turns a turbine, which turns a generator.
The basic components of the plant are:
1. Dam: It holds back water creating a large reservoir
2. Turbine: The water strikes and turns the large blades of a turbine, which is attached to a
generator above it by way of a shaft.
3. Generator: Generator is a device, which converts the Rotary Mechanical Energy in to an
Electrical Energy.
Internship Report Bindagi, Anuj Boving Fouress Ltd. July 31, 2014
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4. Transformer: The transformer inside the powerhouse takes the AC and converts it to
higher-voltage current.
5. The Auxiliaries: The auxiliaries like the Oil Pumping Unit and the Cooling Water
Systems helps in the smooth operation of the power plant. Mechanical Balance of Plant
Hydraulic Power Pack & Oil Pumping
Cooling Water System Dewatering & Drainage System
Compressed Air
Siphon Arrangement
Lubrication
TG PACKAGE
The Turbine and the Generator are collectively known as TG Package. The TG Package along
with its control and monitoring equipment’s are housed in a Civil Structure called the
Powerhouse.
Types of Generators
1. Synchronous generators
A synchronous generator runs at a constant speed and draws its excitation from a power
source external or independent of the load.
Synchronous speed is calculated as follows:
Ns = 120 f / p
It Costs More
2. Induction generators
Induction Generators are special purpose motors that runs at super synchronous speed
(speed slightly above the synchronous speed) i.e at negative slip, and it draws excitation
power from grid.
Slip = (Ns – N) /NS
It Costs Less
Internship Report Bindagi, Anuj Boving Fouress Ltd. July 31, 2014
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TURBINE
Hydraulic turbines are the machines which convert the kinetic and potential energies
possessed by water into mechanical rotary motion or power. Hydro turbines are classified as:
Impulse turbine
Reaction turbine
The difference between these two turbines is that, in an impulse turbine, the whole of the
pressure of energy of the water is converted into kinetic energy before it tis passed onto the
turbine wheel, whereas in a reaction turbine the water flows with both pressure and kinetic
energies over the moving blades where it’s part of the pressure energy is converted into kinetic
energy.
Pelton Wheel
It is an impulse turbine, works under high head and requires small quantity of water.
Water from a high head source is supplied to the nozzle. The pressure energy of water is
converted into kinetic energy. The high velocity water impinges on the curved blades. This sets
up the pelton wheel to rotate in the direction of the impinging jet. Thus, the pressure energy is
converted into mechanical energy.
Internship Report Bindagi, Anuj Boving Fouress Ltd. July 31, 2014
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Francis Turbine
It is a medium head reaction turbine in which water flows radially inwards. Water at high
pressure enters through the inlet and flows radially inwards through the guide blades. The water
flows inwards and finally discharges at the center at low pressure. During its flow, it imparts
kinetic energy to the runner to set it into rotational motion.
Francis Turbine (Reaction)
Kaplan Turbine
It is a low head reaction turbine in which water flows axially. Most of the parts of the
turbine are like that of Francis turbine except the runner. The water at high pressure enters the
turbine casing through the inlet and strikes the guide blades axially imparting kinetic energy to
set it into rotational motion.
Internship Report Bindagi, Anuj Boving Fouress Ltd. July 31, 2014
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OUTPUT OF A HYDRO POWER PLANT
P = 9.81xHxQxη where,
P = The power generated in kilo watts
H = The head measured in meters
Q = The discharge measured in m³/sec.
η = The efficiency of the plant i.e., the combined efficiency of the turbine, generator,
transformer (normally between 0.80 to 0.85)
The output power is measured in kilo watts or megawatts and is dependent on the head and
discharge available for the machine.
The Revenue
The revenue from the plant is the number of units the plant generates multiplied by the
unit price of sale of each unit.
Revenue = No. of units generated x Unit Rate
No. of units generated = capacity of the plant in kws x24hrs of a day x365days of a year x the
rate per unit.
Internship Report Bindagi, Anuj Boving Fouress Ltd. July 31, 2014
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Below is a small article published in “The Hindu “on July 27th which gives a general idea of the
worth of a hydro power plant.
http://www.thehindubusinessline.com/companies/rpower-to-buy-jaypee-group-hydro-projects-
for-15000-cr/article6254869.ece
5 ‘S’ SYSTEM
5S is a housekeeping system to reduce waste and optimize productivity through maintaining an
orderly workplace and using visual posters and imagery to achieve consistent results.
The 5S pillars, Sorting Out (Seiri), Orderly arrangement(Seiton), spic and Span(Seiso),
Standardize (Seiketsu), and Sustain (Shitsuke), provide a methodology for organizing, cleaning
and sustaining a efficient and clean work environment.
SEIRI
Sorting out techniques which involve eliminating unnecessary items from the workplace that are
not needed for current production operations. An effective method used to identify these
unneeded items is called "red tagging". A red tag is placed on all items that are not important for
operations. Once the red tag items are identified, these items are then moved to an outer space
Internship Report Bindagi, Anuj Boving Fouress Ltd. July 31, 2014
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area or the ‘Rejected Items’ area for subsequent disposal or recycling. Sorting enables to reclaim
valuable floor space and eliminate unnecessary items.
SEITON
Systematic arrangement
Layout improvement and marking
It focuses on creating efficient and effective storage methods to arrange items so that they are
easy to use. This can only be implemented once all the unnecessary items have been eliminated
(SEIRI). It includes painting floors (Green and Yellow), sticking labels and tags on every
component to designate its proper storage locations, outlining work areas and locations.
SEISO
Spic and Span
Regular and methodical cleaning
Seiso is thorough cleaning of the area, tools, machines and other equipment to ensure that
everything is returned to a ‘clean’ status. This will ensure that if any defect stands out such as an
Internship Report Bindagi, Anuj Boving Fouress Ltd. July 31, 2014
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oil leak from a machine is being addressed. It ensures standardized ways of working that will
help remove the wastes from the processes and manufacturing areas.
SEIKETSU
Standardization and prevention
Standardize the best practices in the work area and create a consistent approach with which tasks
are done. The second part is prevention which includes preventing accumulation of dust or
cobwebs, preventing accumulation of unneeded items and preventing equipment and materials
from getting dirty.
SHITSUKE
Self-discipline and consistency in replacing items.
Ensuring you and others follow the system.
Sustain, making a habit of properly maintaining correct procedures. Sustain focuses on defining
a new status and standard of work place organization. Tools for sustaining 5S include signs and
posters, team management and performance reviews.
FEATURES of 5 ‘S’
Place for everything and everything in its place.
Scrap disposal time indication
Stock control
Wet to dry concept
Safety and health maintenance
AOP- ANNUAL ORGANIZATION PLAN
Once order is obtained from many companies, a plan is made according to the company’s
capacity and capability. The customer is then promised the entire time duration for the entire
completion of the order based on the plan. Supply is made in batches and even the money is also
received through batches. This is done so that the production is not delayed for any of the party
and there would not be too much of work load.
Internship Report Bindagi, Anuj Boving Fouress Ltd. July 31, 2014
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The AOP should include:
Provide direction to all the functional areas of the organization.
Define the capacity and limit of the organizations activities in terms of what it will
and will not do.
Synchronize the organizations activities to its resource capacity.
SUPPLIER ASSESSMENT
It is a process of evaluating and approving potential suppliers by quantitative assessment.
Supplier evaluation is also a process applied to current suppliers to measure and monitor their
performance for the purposes of reducing costs and increasing efficiency.
This is mainly applied to the components that are outsourced to other suppliers or job shops.
Payment is normally on the credit basis depending upon the supplier. Supplier receives payment
only after the final component is delivered to the customer by the company. By this, personal
investment is controlled. If the component supplied by the supplier is faulty, a Non-Conformance
Report is generated.
In general, the NCR dispositions are:
Use as is
Rework (bringing the item into a state of conformance to specifications)
Repair (fixing the item so that it will work as intended, although it might not
meet the original specifications)
Scrap
If the component is still used and approved by QA that it would not affect the final
performance of the machine, the supplier is made to provide another component if rejected by
the customer.
MAIN STORES
Materials purchased are stored in a well identified location. Store room is identified as
Heavy Components, Electrical Stores and Tool crib. Consumables like fasteners, tools,
packaging material, cotton waste and other production resource tools are stored in tool crib.
Internship Report Bindagi, Anuj Boving Fouress Ltd. July 31, 2014
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Goods Receipt Note (GRN):
The GRN preparation is a part of effective Inventory Control Management.
Record of goods received at the point of receipt. This record is used to confirm all goods have
been received and often compared to a purchase order before payment is issued. Official
document issued by a company to acknowledge receipt of items listed in it.
Goods Receipt Note is a document used to record the inward entry of the any goods received at
the premises of the organization. The document normally consists of the details of Quantity
Received, Quantity Rejected and Quantity Accepted, Supplier Name & P.O. No. The practice of
preparing GRNs is important as it promotes proper inventory control and restricts the unwanted,
unauthorized entry of goods in the organization.
Reasons for delay in the preparation of GRNs:
Weight difference in receipt of castings and fabricated items from supplier.
Non-receipt 57F(4) challan for items on job work
Non-receipt of duplicate for transported and Original for buyers from supplier.
3 forms are generally issued from the stores. They are:
Original + Tax Invoice – goes to the accounts department for billing
Duplicate – goes to supplier if required
Triplicate – always with the stores department
3 types of cards/tags present on the components:
Yellow – Inventory card
Blue – Accepted items
Red – Rejected Items
The inventory card normally contains information about the location of storage of the
component.
Internship Report Bindagi, Anuj Boving Fouress Ltd. July 31, 2014
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The blue (accepted by stores) card has the GRN No., Description & quantity of the component
and the project name.
The red (rejected) card consists of the quantity of rejected items and the reason for its
disapproval.
Store will prepare dispatch documents based on Shipping Memorandum & dispatch request and
co-ordinate for dispatch. Stores issue Annexure forms for job works or any other vendor works
which does not require Tax Invoice/ VAT.
They also issue Returnable Gate Pass (RGP) to vendors which require assistance from the stores
for the completion of job. Non-Returnable Gate Pass (NRGP) is issued for the items/ goods that
cannot be returned to the company as it is consumed during the completion of the job.
Stores will assist and provide packing boxes and required material for packing.
The size & dimension of the packing material are mentioned for which item it is required along
with its code.
Internship Report Bindagi, Anuj Boving Fouress Ltd. July 31, 2014
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Assembly/Parts received from job site – Stores shall receive, verify & identify items as per the
document & inform contracts department.
Stores issues an E-SUGAM form for goods. This form is used to pass the check posts during
delivery. For dispatch, the item code and tax invoice is sent which is an online form.
CALIBRATION TECHNIQUES
Calibration of micrometer
OD Micrometer
Instrument description
External micrometer (Mitutoyo)
Range: 0-25 mm
LC: 0.01 mm
Master used for calibration
Slip gauge set size 0.5 – 100 mm
Linear height gauge
Actual measured value = Instrument reading ~ Error
ID Micrometer
Instrument description
Stick micrometer (Mitutoyo)
Range: 50-1500 mm
Master used for calibration
Slip gauge set 0.5 -100 mm
Linear height gauge
General Procedure for the calibration of micrometer
The device to be calibrated is cleaned using a solvent
It is transferred to the Lab where it undergoes 4hrs of compulsory soaking
The device is adjusted to the conditions of the lab like humidity and temperature
Internship Report Bindagi, Anuj Boving Fouress Ltd. July 31, 2014
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Slip gauge sets of different range is used
3 different trials are used to calibrate the error
The lab in charge verifies using ISO standards
Calibration of Pressure gauges
External pressure sensor with indicator and using comparison with digital pressure gauge (DPI)
Absolute pressure gauge is calibrated using digital absolute pressure gauge
Bore Gauges- EDCT with Sylvac
Compound gauges – Digital pressure calibrator
NON-DESTRUCTIVE TESTING (NDT)
It is a way of testing without destroying. This means that the component- the casting, weld or
forging, can continue to be used and that the non-destructive testing method has done no harm.
NDT can be used to ensure the quality right from raw material stage through fabrication and
processing to pre-service and in-service inspection.
Dye – penetrant testing
Dye penetrant testing examines the surface of an item (nondestructively) for cracks. A liquid
penetrant is applied to the surface and left to soak. The liquid is drawn into any cracks via
capillary action. The liquid is typically brightly colored or a fluorescent (under UV light) dye.
The developer is usually a dry white powder (for example chalk powder) suspension that is
spayed on the component. The developer is drawn out of the crack by reverse capillary action,
resulting in a colored indication on the surface that is broader than the actual flaw, and therefore,
much more visible. This technique can be used to detect surface flaws on essentially any non-
porous material.
Magnetic Particle Test (MPT)
Magnetic Particle Inspection (MPI) or Magnetic Test (MT) is a non-destructive test method for
the detection of surface and sub-surface discontinuities in ferrous materials. The test method
involves application of magnetic field externally or applying electric current through the material
Internship Report Bindagi, Anuj Boving Fouress Ltd. July 31, 2014
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which in turn produces magnetic flux in the material. The presence of a surface or near surface
discontinuities in the material causes distortion in the magnetic flux which in turn causes leakage
of the magnetic fields at the discontinuity. The magnetic particles are attracted by the surface
field in the area of the discontinuity and adhere to the edges of the discontinuity appearing the
shape of the discontinuity.
Magnetic particle test (MT) is very sensitive test method. Magnetic Particle Inspection cannot be
used for non-ferrous materials and non-magnetic ferrous materials such as austenitic stainless
steels.
Internship Report Bindagi, Anuj Boving Fouress Ltd. July 31, 2014
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ACKNOWLEDGEMENT
I immensely thank Boving Fouress for giving me this opportunity to undergo the training
program.
I express my sincere gratitude to Mr. Deepak Kumar who mentored me in my brief stay at
Boving Fouress. I would also like to thank Mr. Arun (HR-dept), Mr. Patil, Mr.Jayram &
Mr.Nagaraj. Also, my special thanks to all the employees at bfl who have constantly cleared all
my queries and helped me understand the underlying process effectively.
I would also like to commend the canteen for the wonderful food.
I will always be grateful to the HOD of Mechanical Engineering, PESIT and the whole of the
department for the opportunity given to me to learn and experience new technology and get an
insight into how industry works.