BFL Report

Internship Report Bindagi, Anuj Boving Fouress Ltd. July 31, 2014

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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.


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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.


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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


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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.


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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.


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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.


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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

http://www.thehindubusinessline.com/companies/rpower-to-buy-jaypee-group-hydro-projects-for-15000-cr/article6254869.ece

http://www.thehindubusinessline.com/companies/rpower-to-buy-jaypee-group-hydro-projects-for-15000-cr/article6254869.ece


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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


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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.


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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.


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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.


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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.


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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


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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


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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.


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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.

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