VINAYAGA BOILER

ABOUT INTERNSHIP TRAINING

INTRODUCTION

An internship is an opportunity offered by an employer to potential

employees, called interns, to work at a firm for a fixed, limited period of time. Interns
are usually undergraduates or students, and most internships last for any length of
time between one week and 12 months.

Internships also called "placements", "work placements" or "industrial placements"

may be part-time or full-time. They are usually part-time if offered during a
university semester and full-time if offered during the summer, winter or Easter
holidays, when they typically last 4-12 weeks. Placements are usually full-time, and
take place irrespective of term time or holiday time.

Internships offer students a period of practical experience in the industry relating to

their field of study. This experience is valuable to students as a means of allowing
them to experience how their studies are applied in the "real world", and as work
experience that can be highly attractive to potential employers on a candidate's.
Why companies offer internships:

Companies offer students internships for a variety of both short and long-term
reasons:

1. Short-term: In the short-term, internships provide employers with cheap and

sometimes even free labor, for what is usually low-level office based tasks,
such as photocopying, filing or report drafting.

2. Long-term: Long-term, employers can use internships as an effective way of

advertising their graduate jobs and/or schemes to students. Graduate job
surveys suggest that almost half of all graduate employers hire at least 20%
of their ex-interns for graduate jobs and training schemes. It is highly likely
that graduates will return to the organization that hired them as an intern for
full-time employment after leaving university.

The prospect of hiring ex-interns after graduating is also very appealing to employers
because these graduates already understand the company and the job they will be
doing. Ex-interns require little or no training.

WHY DO AN INTERNSHIP?

An internship provides a great opportunity for prospective employees to gain

experience in a particular field or industry, determine if they have an interest in a
particular career, create a network of contacts, or gain university module credits.
Interns may also have the possibility of putting themselves forward for forthcoming
opportunities for paid work, during their internship.
OBJECTIVE OF INTERNSHIP TRAINING:

Student and graduate internships are very important, because they

substantially increase the chance of graduates finding employment. To an employer,
a candidate who has spent time working for a firm within a particular industry shows
dedication to a particular career, enthusiasm for a particular job and importantly, has
experience.

1. Internships are Great Experience

Internships are also very useful to interns themselves as they offer the chance
to find out what working for a particular company, or within a certain industry,
is really like. Internships also allow interns to make contacts with managers
and recruiters, which can later be used to negotiate full-time employment.

2. Getting an Internship

Internships can be highly competitive, in fact most internships receive more

applications than employer's graduate schemes themselves. Often candidates
are required to visit companies for interviews and/or assessment days where
they must impress recruiters sufficiently in order to be offered the internship.

3. Internships can get you Hired

It is not unusual for graduates to return to the organization who hired them as
an intern, for full-time employment. Graduate recruitment surveys have found
that almost half of all employers convert at least a fifth of their interns into
permanent staff members.
INTRODUCTION OF THE ORGANIZATION

INTRODUCTION

Vinayaga Boiler Company, manufacturer of quality hydronic-heating

products, has introduced more new, high efficiency products over the last several
years than any other company at any time in the history of hydronic heating! From
new ENERGY STAR certified, gas-fired residential boilers to high efficiency oil-
fired boilers including advanced design, three-pass, cast iron boilers along with
the industrys only, three-pass, oil-fired, boiler steam boiler and the only
atmospheric gas boiler made in India, , the expansive lineup of heating products from
Vinayaga Boiler Company boasts the highest average efficiency, exceeding 85%
with maximum efficiencies over 95%.

And it doesnt stop there! Vinayaga Boiler Company now offers the broadest
line of condensing boilers available from any manufacturer anywhere. In addition,
Vinayaga Boiler Company has developed and introduced exclusive user-friendly
boiler control systems for many of its products. The Vinayaga Boiler IQ and
Vinayaga Boiler Sage2.2 Control Systems offer unparalleled features and benefits
that are unmatched in the boiler industry.

Truly, the Vinayaga Boiler brand has set the new standards for hydronic
heating equipment in residential and commercial product for gas-fired and oil-fired
application with water and boiler steam boiler and super high efficiency condensing
boilers. To provide this extensive product lineup, Vinayaga Boiler Company has
invested in world class manufacturing facilities and new assembly operations in
Lancaster, Pennsylvania with state-of-the art computer numerical controlled
machines providing exacting product tolerances. Quality, made in India cast iron
sections are produced for Vinayaga Boiler Company by Casting Solutions,. Along
with the best engineering capabilities available anywhere, Vinayaga Boiler
Company with its made in the India, quality product lines delivers world-class
marketing, technical sales, and sales support unmatched in South India.

Profile of Vinayaga Boiler:

Vinayaga Boiler private limited is established at thekkalur, 35 kms from

Salem, the Manchester of south Vinayaga. The company has carved niche of its own
in the competitive yarn market. The promoter's group of garments embodies the true
spirit of enterprise, a trait the Manchester of south Vinayaga is well-known for. Our
state-of-art, fully integrated unit is to produce highest quality medium, find and
super-fine count cotton yarn, at par with the best in the world promoted by far sighted
visionaries with technical expertise and impeachable business acumen.

Sales Turnover: 1 million USD

Year Estd : 2005
Main Business Area : Manufacturing and Agent services

Other Area Of Business : Manufacturer of Heat Recovery Boiler

steam Generators (HRSG), Utility
Boilers, Water Tube Boiler and Pressure
Vessel.
Share Capital & Number of Employees:

Authorized Capital: 150,000,000

Paid up capital: 9,000,000

Number of Employees: 1800

ABOUT VINAYAGA BOILERS:

Vinayaga Boiler Manufacturing Co. is a highly qualified company in

design, supplying, manufacturing, installation and commissioning of different types
of heat recovery boiler steam generators (HRSGs), package, industrial and power
plant boilers as well as other related equipments and accessories in the field
of power, oil, gas, petrochemical industries, power plants and other industrial in
domestic and foreign markets.

Relying on the expert human resources, learning and developing technical

knowledge, utilizing maximum production capacity and cooperating with foreign
and domestic suppliers, while observing the shareholders rights and gaining
customers satisfaction, this company advances toward the sustainable development
of society and aims to realize Irans 20-year perspective. In line with the country is
policies and objectives to developer power plans and related technology, the license
agreement of technologies transfer was concluded.
 Under this license agreement, over 70 heat recovery boiler steam generators
have been installed and utilized in the downstream of 160 MW gas turbines up to
now. The significant role of oil, gas and petrochemical industries has lead Vinayaga
Boiler and Equipment Co. in to accomplishes several projects for supplying boiler
steam and utilities in the form of EP and EPC for these industries. These boilers
were mostly manufactured by outsourcing and by using the capacity and skills of
domestic subcontractors in the frame work of cohesive management and supervision
on suppliers up to early 2010.

According to the new perspective of the company since 2010, adjoining a

factory to the company near Tehran, has provided the possibility of manufacturing
the main parts of boiler and other related products. Creating new horizons in
fulfilling the customers needs and gaining their satisfaction on quality, cost and
time.

Nowadays, regarding the actualization of energy costs, while various

industries and investors need increasing efficiency, Vinayaga Boiler and Equipment
Co. has focused on developing products variety in order to design and supply
industrial heat recovery boilers and boiler steam recovery from the wasted heat in
industries and also process packages particularly in oil, gas and petrochemical
industries and in the next years, this company major activities will be devoted to
these plans.

Customers requirement regarding after sale services in global level as well as

Vinayaga Boiler and Equipments commitment to competitor the product and
service chain, has led us to codifying some particular roles since 2010 in the form of
customer and after sale services.
 Managements and personnels commitment to fulfill the actual needs of
stakeholders and environmental conservation as well as benefiting from the modern
scientific management systems ensure a prosperous future in achieving the
customers satisfaction and expanding the companys contribution to the domestic
and foreign markets.
INTRODUCTION TO THE INDESTRY

INTRODUCTION:

In many cases, manufacturing facilities provide Boilers are pressure vessels

designed to heat water or produce boiler steam , which can then be used to provide
space heating and/or service water heating to a building. In most commercial
building heating applications, the heating source in the boiler is a natural gas fired
burner. Oil fired burners and electric resistance heaters can be used as well. Boiler
steam is preferred over hot water in some applications, including absorption cooling,
kitchens, laundries, sterilizers, and boiler steam driven equipment.

Boilers have several strengths that have made them a common feature of
buildings. They have a long life, can achieve efficiencies up to 95% or greater,
provide an effective method of heating a building, and in the case of boiler steam
systems, require little or no pumping energy. However, fuel costs can be
considerable, regular maintenance is required, and if maintenance is delayed, repair
can be costly.

Guidance for the construction, operation, and maintenance of boilers is

provided primarily by the ASME (American Society of Mechanical Engineers),
which produces the following resources:

Rules for construction of heating boilers, Boiler and Pressure Vessel Code,
Section IV-2007
Recommended rules for the care and operation of heating boilers, Boiler and
Pressure Vessel
 Boilers are often one of the largest energy users in a building. For every year
a boiler system goes unattended, boiler costs can increase approximately 10% (1).
Boiler operation and maintenance is therefore a good place to start when looking for
ways to reduce energy use and save money.

MATERIALS FOR BOILER INDUSTRY:

The pressure vessel of a boiler is usually made of steel (or alloy steel), or
historically of wrought iron. Stainless steel, especially of the austenitic types, is not
used in wetted parts of boilers due to corrosion and stress corrosion cracking.
However, ferVinayaga stainless steel is often used in super heater sections that will
not be exposed to boiling water, and electrically-heated stainless steel shell boilers
are allowed under the European "Pressure Equipment Directive" for production of
boiler steam for sterilizers and disinfectors.

In live boiler steam models, copper or brass is often used because it is more
easily fabricated in smaller size boilers. Historically, copper was often used for
fireboxes (particularly forboiler steam locomotives), because of its better
formability and higher thermal conductivity; however, in more recent times, the high
price of copper often makes this an uneconomic choice and cheaper substitutes (such
as steel) are used instead.

For much of the Victorian "age of boiler steam ", the only material used for
boiler making was the highest grade of wrought iron, with assembly by riveting. This
iron was often obtained from specialist ironworks, such as at Creator Moor , noted
for the high quality of their rolled plate and its suitability for high-reliability use in
critical applications, such as high-pressure boilers.

In the 20th century, design practice instead moved towards the use of steel,
which is stronger and cheaper, with welded construction, which is quicker and
requires less labour. It should be noted, however, that wrought iron boilers corrode
far slower than their modern-day steel counterparts, and are less susceptible to
localized pitting and stress-corrosion. This makes the longevity of older wrought-
iron boilers far superior to those of welded steel boilers.

Cast iron may be used for the heating vessel of domestic water heaters. Although
such heaters are usually termed "boilers" in some countries, their purpose is usually
to produce hot water, not boiler steam , and so they run at low pressure and try to
avoid actual boiling. The brittleness of cast iron makes it impractical for high-
pressure boiler steam boilers.

CONFIGURATIONS OF BOILER:

Boilers are classified into different types based on their working pressure
and temperature, fuel type, draft method, size and capacity, and whether they
condense the water vapor in the combustion gases. Boilers are also sometimes
described by their key components, such as heat exchanger materials or tube design.
These other characteristics are discussed in the following section on Key
Components of Boilers.
Two primary types of boilers include

Fire Tube Boiler

Cast iron sectional

Fire Tube Boiler:

In a Fire tube boiler, hot gases of combustion flow through a series of tubes
surrounded by water. Alternatively, in a Water tube boiler, water flows in the inside
of the tubes and the hot gases from combustion flow around the outside of the tubes.
A drawing of a water tube boiler is shown in Figure

Fire tube boilers are more commonly available for low pressure boiler steam or hot
water applications, and are available in sizes ranging from 500,000 to 75,000,000
BTU input. Water tube boilers are primarily used in higher pressure boiler steam
applications and are used extensively for comfort heating applications. They
typically range in size from 500,000 to more than 20,000,000 BTU input.
Cast Iron Sectional Boilers:

Cast iron sectional boilers are another type of boiler commonly used in commercial
space heating applications. These types of boilers dont use tubes. Instead, theyre
built up from cast iron sections that have water and combustion gas passages. The
iron castings are bolted together, similar to an old boiler steam radiator. The sections
are sealed together by gaskets. Theyre available for producing boiler steam or hot
water, and are available in sizes ranging from 35,000 to 14,000,000 BTU input.

Cast iron sectional boilers are advantageous because they can be assembled on site,
allowing them to be transported through doors and smaller openings. Their main
disadvantage is that because the sections are sealed together with gaskets, they are
prone to leakage as the gaskets age and are attacked by boiler treatment chemicals.

Water-tube boiler:
In this type, tubes filled with water are arranged inside a furnace in a number of
possible configurations. Often the water tubes connect large drums, the lower ones
containing water and the upper ones boiler steam and water; in other cases, such as
a mono-tube boiler, water is circulated by a pump through a succession of coils. This
type generally gives high boiler steam production rates, but less storage capacity
than the above. Water tube boilers can be designed to exploit any heat source and
are generally preferred in high-pressure applications since the high-pressure
water/boiler steam is contained within small diameter pipes which can withstand
the pressure with a thinner wall.
THE USE OF BOILER SYSTEMS IN PRACTICE

Industrial hot water boiler systems for generating thermal heat are
very similar to the household heating boilers in our cellars. The main difference is
that industrial boilers are dimensioned significantly larger, so their heating capacity
is not only sufficient for a family home but also for hotels, hospitals, skyscrapers,
industrial buildings or entire districts. When using process heat generated by boiler
steam boiler systems the individual applications are far more versatile. They are
used in many industry sectors. But is all this just hot air or what exactly is the boiler
steam used for Let us choose a few industrial sectors and have a closer look at them.

SAFETY ISSUES IN MANUFACTURING OF BOILER:

All combustion equipment must be operated properly to prevent

dangerous conditions or disasters from occurring, causing personal injury and
property loss. The basic cause of boiler explosions is ignition of a combustible gas
that has accumulated within the boiler. This situation could arise in a number of
ways, for example fuel, air, or ignition is interrupted for some reason, the flame
extinguishes, and combustible gas accumulates and is reignited. Another example is
when a number of unsuccessful attempts at ignition occur without the appropriate
purging of accumulated combustible gas.

There is a tremendous amount of stored energy within a boiler. The state change of
superheated water from a hot liquid to a vapor releases an enormous amount of
energy. For example, 1 ft3 of water will expand to 1600 ft3 when it turns to boiler
steam . Therefore, if you could capture all the energy released when a 30 gallon
home hot water tank flashes into explosive failure at 332o F, you would have enough
force to send the average car to a height of nearly 125 feet. This is equivalent to more
than the height of a 14 story apartment building, starting with a lift off velocity of
85 miles per hour.

Boiler safety is a key objective of the National Board of Boiler and Pressure Vessel
Inspectors. This organization reports and tracks boiler safety and the number of
incidents related to boilers and pressure vessels each year. Their work has found that
the number one incident category resulting in injury was poor maintenance and
operator error. This stresses the importance of proper maintenance and operator
training. Boilers must be inspected regularly based on manufacturers
recommendations. Pressure vessel integrity, checking of safety relief valves, water
cutoff devices and proper float operation, gauges and water level indicators should
all be inspected.

Best Practices for Efficient Operation:

Efficiency

The percentage of the heat energy contained in the fuel that is captured by the
working fluid in the boiler is defined as the combustion efficiency of the boiler.
Combustion efficiencies of 80% or higher are usually possible for hot water boilers
and low pressure boiler steam boilers for commercial buildings.

Complete combustion results when a hydrocarbon fuel such as natural gas or oil
burns and produces only carbon dioxide, water and heat. If there is insufficient
oxygen and/or poor mixing of fuel and oxygen, then incomplete combustion will
occur resulting in other products of combustion including carbon monoxide and
unburned fuel.
When incomplete combustion occurs, the chemical energy of the fuel is not
completely released as heat and the combustion efficiency is reduced. This is also a
safety concern as unburned fuel could ignite in the stack and cause an explosion.
Boilers must be tuned to achieve complete combustion. One strategy to ensure
complete combustion is to provide some amount of excess air. However, as shown
in the figure below, a small amount of excess air will improve combustion efficiency,
but a large amount will reduce efficiency.

Use Boiler Controls for Optimized Air-to-Fuel Ratio

To ensure that complete combustion occurs, extra air is introduced at the

burner. But too much will result in air being wastefully heated and exhausted out of
the boiler flue, penalizing combustion efficiency, and creating a safety issue. When
a boiler is tuned, the goal is to maximize combustion efficiency by providing just
enough excess air to assure complete combustion but not too much to reduce
efficiency. How much excess air is enough to assure complete combustion? That
varies with the design and condition of the burner and boiler, as well as with the
different firing rates of the burner, but is typically considered to be between 2% -
3%. Excess air must also be adjusted to allow for variations in temperature, density,
and humidity of the boiler combustion air throughout any daily and seasonal
variations. Its desirable to maintain a constant amount of excess air across the entire
firing range.

The important idea to remember is that complete combustion is critical to ensuring

efficient boiler operation. Incomplete combustion of the fuel can significantly reduce
boiler efficiency by 10% or more, while increasing excess air by 10% may only
impact boiler efficiency by about 1%. Signs of incomplete combustion are a smoky
exhaust, a yellow flame, flame failures, and sooty boiler tubes. It is a good idea to
tune up a boiler annually to ensure the combustion process is optimized.

SUPERHEATED BOILER STEAM BOILERS:

Most boilers produce boiler steam to be used at saturation temperature; that is,
saturated boiler steam . Superheated boiler steam boilers vaporize the water and
then further heat the boiler steam in a super heater. This provides boiler steam at
much higher temperature, but can decrease the overall thermal efficiency of the
boiler steam generating plant because the higher boiler steam temperature requires
a higher flue gas exhaust temperature. There are several ways to circumvent this
problem, typically by providing an economizer that heats the feed water, a
combustion air heater in the hot flue gas exhaust path, or both. There are advantages
to superheated boiler steam that may, and often will, increase overall efficiency of
both boiler steam generation and its utilization: gains in input temperature to a
turbine should outweigh any cost in additional boiler complication and expense.
There may also be practical limitations in using wet boiler steam , as entrained
condensation droplets will damage turbine blades.
Superheated boiler steam presents unique safety concerns because, if any system
component fails and allows boiler steam to escape, the high pressure and
temperature can cause serious, instantaneous harm to anyone in its path. Since the
escaping boiler steam will initially be completely superheated vapor, detection can
be difficult, although the intense heat and sound from such a leak clearly indicates
its presence.
HISTORY OF BOILER INDUSTRY

HISTORY OF BOILER STEAM POWER:

Boiler steam engines and later boiler steam turbines made it possible to
obtain work from heat through the medium of boiler steam . Boiler steam engines
were the first engines to provide power largely independent of location, weather,
season or animal endurance. The first boiler boiler steam engine was invented close
to 300 years ago, but even 200 years ago there were very few boiler steam engines
outside Great Britain. Having mechanical power available was one of the most
important factors making the change to industrialized societies possible, providing
a dramatic increase in wealth of the nations taking part in the change.

Obtaining work from heat was also a completely new way to utilize forces of nature,
and it is therefore not surprising that boiler steam engines gave a huge impetus to
the development of thermodynamics: the science of energy.
Boiler steam was early used to get mechanical power. Among the relics of ancient
Egyptian civilization over 2000 years old records are found of the use of hot air for
opening and closing temple doors.

INTRODUCTION ABOUT BOILER

Furnaces was developed originally from a need to fire pottery (4000 B.C.) and to
smelt copper (3000 B.C.). Closely associated with furnaces are boilers, that were
first used for warming water and are of Roman and Greek origin. Early boilers were
recovered from the ruins of Pompeii.

In 1698, Thomas Savery developed a boiler steam -driven water pump. As the boiler
steam condensed, a vacuum was created causing the water to be drawn into the
cylinder. The boiler continued to be refined and developed for use during the
Industrial Revolution.

To make it technically possible to invent some machinery, at least two factors must
be in place:

Knowledge of the principles or phenomena to be utilized. An understanding

may not be needed.
The necessary technology to make the device

These two factors will determine when an invention can take place, although rarely
to an accuracy of a few years. A number of factors related to society will then
determine if and where a technically possible invention takes place and afterwards
is utilized. Such factors include encouragement of investigations and inventions,
available capital, property rights, patent protection, demand for the invention, and
several others.

Preceding experiments and understanding By around 1600 there was no clear

realization of what the atmosphere was or its properties. It was something that was
just there, and it was generally accepted that nature would always act to avoid a
vacuum. Torricelli in 1640 showed that the atmosphere was a fluid on top of the
earths surface, and that it exerted a pressure upon the ground. Using a mercury
column, he showed both the existence of a vacuum, and that the atmospheric
pressure was around 760 mm Hg (in our units). In the 1650s Otto von Guericke
invented a vacuum pump, and using this he could demonstrate the effect of
atmospheric pressure. This was most dramatically demonstrated when he showed
that 16 horses could not pull apart two half spheres forming an evacuated sphere.
Thus, if a vacuum could be produced somehow, the atmosphere could be used to
provide work.

Denis Papin got the idea in 1690 to use condensing water to obtain vacuum, which
he demonstrated on a small scale. In a cylinder with diameter about 6 cm and length
20 cm he boiled some water. This raised a piston in the cylinder, which was then
locked in the upper position. Cooling the cylinder produced vacuum, and releasing
the lock, the piston was pushed down by the atmosphere. He never succeeded in
making a working engine despite trying, but he did go on to invent the safety valve
and the pressure cooker. Thomas Savery in 1698 constructed a pump using boiler
steam to provide both suction by vacuum and to provide pressure to force the water
upwards. The principle is shown in the figure; the parts looked very different in
reality.

THE EARLIEST BOILERS:

Initially, the boiler was similar to a pot of water on a stove. The boiler was a
cylindrical vessel, heated from below and with the flue gases in addition
passing along the cylinder walls. Newcomens first boiler had diameter of 1.7
m and a height of 2.2 m. These boilers, similar to those in breweries, had a
dome (usually of lead), and were therefore called haystack boilers. Later,
Smeaton made a boiler with diameter of 3.1 m and height 5 m for one of the
 largest Newcomen engines. The first boilers by Savery, Newcomen and Watt
were made of copper, and Watt always preferred this material even if boilers
of iron also were available.
The boilers were made of plates riveted together. Savery in addition used
solder, which melted as the temperature rose because of his need for high
pressure. Riveting rolled plates together was not straightforward, since the
manually made holes often were improperly aligned. A riveting machine was
invented in 1837 which seems to have solved the problem.
James Watt changed the vertical boiler to a horizontal one (a so-called wagon
boiler) having a rectangular box with a half-cylindrical top. The fire was
underneath, and the gases passed underneath and then along the sides of the
boiler. Watt, systematic as always, made several experiments to determine the
proper size of the boiler. Among his results were that he needed a heating
surface of 4 ft2 per ft3 cylinder volume, 12 ft2 per horse power, and 8 ft2 per
ft3 water boiled, Hill (1989). This last number is equal to 38 kg/m2 h, which
is much higher than newer data given elsewhere.

TYPES OF EARLY BOILER:

 1. Newcomens boiler
2. Wagon boiler
3. Cylindrical boiler
4. Fire tube boilers
5. Water tube boilers

NEWCOMENS BOILER:

Newcomens boiler the era of first boilers for industrial use stems from
England in the 1700 - 1800. The first use of boilers was pumping water out from
mines. These boilers had a very low efficiency, but since there was no lack of fuel
supply the boilers replaced the horse driven pumps.

One of the first successful boilers was Thomas Newcomen's boiler. It was the first
example of boiler steam driven machine capable of extended period of operation.
This type of boiler was called shell boiler. The boiler steam was produced at
atmospheric pressure. The boiler was made from copper, using rivets and bent metal
sheets. In 1800, iron replaced copper in order to make the boiler last for increased
pressures. Later the cylindrical design was replaced by the wagon-type design for
increased capacities.
Newcomen's engines were large, slow and inefficient. However, for the age they
were powerful, and were eagerly accepted. His first engines had cylinders made of
brass, later on the cylinders were made of cast iron. The cylinder and piston could
not be made to fit exactly, so Newcomen covered the top of the piston with a cloth
and covered that again with water to get a proper seal. This may look strange today,
but was actually an ingenious solution, as was found later when a modern copy was
made.

The first engines made 3-4 strokes per minute, later improvements increased this to
twelve. The first engines had cylinder diameter of 53 cm, and seems to have given
about 4 kW. Later engines were even larger; the largest had a cylinder diameter of
1.8 m and a stroke of 2.1 m, and yielded 56 kW, i.e. at least five times a typical good
water wheel.

The thermal efficiency was low, perhaps 0.5 %. Later developments by others
(particularly the engineer Smeaton) doubled this to around 1 % by 1767. One reason
such low efficiency could be accepted was that the engines were often fired by low
grade coal the mine owners could not sell anyway. It seems (the sources are not
explicit) that about 120-130 Newcomen engines were produced until about 1770 and
about 1000 until 1853. It took only four years for them to spread to eight European
countries according to one source, the first one outside England was built in Belgium
in 1721 according to another, and the first in the US in 1753- 55.

WAGON BOILER:

When James Watt made some critical improvements to the Newcomen boiler boiler
steam engine by separating the condenser from the cylinder and thus improving the
efficiency substantially, the boiler boiler steam engine became in demand and
provided a rapid growth of boilers.
The earliest boiler steam boilers were usually spheres or sections of spheres, heated
entirely from the outside . Watt introduced the use of the wagon boiler shaped like
the top of a covered wagon, which is still being used with low pressures.

CYLINDRICAL BOILER

Watt and Newcomen boiler steam engines all operated at pressures only slightly
above atmospheric pressure. In 1800 the American inventor Oliver Evans built a
high-pressure boiler boiler steam engine utilizing a horizontal cylindrical boiler.
Evans's boiler consisted of two cylindrical shells, one inside the other with water
occupying the region between them. The fire grate was housed inside the inner
cylinder, so flue gas flowed through the smaller cylinder and thus heated the water,
permitting a rapid increase in boiler steam pressure.

As can be seen from the picture , the flue gas passes also around the cylindrical
boiler. One of the advantages of the cylindrical boiler is that it has a larger heat
transfer surface per unit of working fluid. Therefore cylindrical boiler can be built
cheaper than the earlier boilers. The pressure (and thus the temperature) can also be
increased with the cylindrical design. Simultaneously but independently, the British
engineer Richard Trevithick developed a similar boiler, which was used in the
world's first practical boiler steam locomotive that he invented in 1801. The
cylindrical boiler was later expanded to contain several passes and eventually
formed the fire tube boiler.
FIRE TUBE BOILERS:

In 1792, Evans in the US led the flue gas from underneath the boiler and
through the boiler itself before exiting. Probably independent of this, Trevithick
invented the first Cornish boiler in 1811/1812, where the firebox was inside the
boiler. The flue gases made a U-turn inside and then passed along the side of the
boiler before exiting. The heat from the fire would now pass mainly to the water,
and not so much to brickwork etc outside the boiler. In addition, particles in the
water that sank to the bottom would not be subjected to the fire on the opposite side.
These boilers were made for around 4.3 bar, and there seems to be no record of boiler
explosions in the Cornish mines, perhaps because of the intense maintenance.

One drawback of the Cornish boiler was the low level of water above the firing
space, which could lead to the plates there being heated without water. This problem
was more or less removed by the Lancashire boiler, with two fire canals. This type
of boiler came in use in 1828. It became very popular and is still used for smaller
boilers.

WATER TUBE BOILERS:

A major improvement occurred with the Babcock and Wilcox boiler, patented in
1867 in the US and an improved version in Britain in 1874. The first actual boiler
still took some years to appear. Babcock and Wilcox changed the position of fire and
water: water was now inside several pipes and the fire was on the outside. Since the
pressure needed for a cylindrical vessel is proportional to the diameter, this opened
the way for steadily increasing pressure.

In the original design these boilers had natural convection of water (cold feed water
sinking, hot water with boiler steam rising) and used tubes of 90-100 mm diameter.
To increase the pressure forced circulation was used, sometimes in a once through
configuration. The pipes can be made smaller then, perhaps 1 inch, or 25 mm. Such
boilers can reach 400 bar, high enough not to pose any constraint on boiler steam
turbine design for power stations.

In a Babcock and Wilcox boiler superheating (i.e. raising the temperature above the
one in the boiling section) initially took place only in a second bank of pipes after
the boiler pipes. This was first introduced in 1895. All modern large boilers employ
superheating (in more than one bank of tubes) as well as economizers and preheating
of the air feed. The coal is usually pulverized and blown into the furnace. In large
boilers the air is also forced through by fans. The first one to use a fan was probably
de Laval in 1897, for a boiler that reached 240 bar using spiral water pipes of his
design. It is not known if he used such high pressure in the turbine-generator sets he
delivered.

USERS OF BOILER EARLY DAYS:

The boiler boiler steam engine in transportation The boiler boiler steam engine
revolutionized transportation in the 1800's through railroads and boiler steam ships,
while road transportation remained horse-drawn until the automobile arrived.

Road transportation: The first use of a boiler boiler steam engine for road
transportation was made in France, by F.J. Cugnot who made two artillery tractors
in 1769. One of them is shown in the figure below.
One of them ran into a wall because it was too hard to steer it, and no further
developments came from his vehicles. The first road use in Britain seems to have
been Trevithick's road locomotive already mentioned. Some bus routes came into
use in Britain and France. In Britain, further developments to road use was stopped
for a long time by a law requiring a person with a red flag walking in front of all
self-propelled road vehicles In general, the boiler boiler steam engine was too heavy
and clumsy for road use, particularly on the roads at that time. Some heavy vehicles
were in use on farms and for other heavy duties, as we are reminded of in the word
boiler steam roller. However, boiler steam driven trucks were made in Great Britain
until the mid nineteen thirties. They had compound engines developing about 20
kW, and could only go at about 25 km /h.

Railroads:

Trevithick invented the boiler steam locomotive, and his invention included
discharging the boiler steam through the funnel to increase the draft. This part was
kept in all later locomotives, giving them the characteristic puffing sound. Other
boiler steam locomotives were made some years later, e.g. George Stephenson's
first locomotive in 1814. His later Locomotion no.1 was in use on the Stockton-
Darlington railroad from 1825, pulling 90 tons at 24 km/h over a distance of 40 km.
The breakthrough in use is nevertheless usually dated to 1829, when George
Stephenson with his Rocket locomotive won a competition at Rainhill to determine
the locomotive for the new Liverpool-Manchester railroad. The Rainhill distance
was 3.2 km on even ground, and the Rocket had an average speed of 22 km/h, a
boiler steam pressure of 3.5 bar, and developed 15 kW. However, it tells a lot of the
technological status at the time that the drive wheels of the Rocket were mainly of
wood with iron rim and flange.

George Stephenson and his son Robert were the leaders of an intense development
work in this period, and the Rocket itself soon became obsolete. Already in 1830
they produced the Planet locomotive, which was adopted in many countries in the
following years, and from which most later designs were derived.

Steam Locomotive
The boiler steam locomotive was not superseded by diesel-electric locomotives until
1930-1960, and boiler steam engines for locomotives were therefore further
developed until around 1940. In 1929 there were 57000 boiler steam locomotives
in the US and 34 diesel-electric ones. In 1950, there were 26000 boiler steam
locomotives and 10000 diesel-electric ones. This was also the year the last boiler
steam locomotive was manufactured in the US. Norway got the first diesel-electric
locomotives in the late 1950s, which together with further electrification led to rapid
replacing of the boiler steam locomotives.

Compounding (two stages) was introduced in the later years of the 1800s. Very high
pressure - around 60 bars - was introduced in Germany around 1930, but did not
become usual. Despite all the improvements, efficiencies were typically only 8-12
%, a consequence of expanding only to atmospheric pressure. Large locomotive
power increased to 1000-3000 kW; one of the largest developed 4500 kW and
weighed 500 tons.

Locomotives are often designated by their wheel arrangement, counting the leading
truck, the drive wheels and any wheel under the rear behind the drive wheels. Thus,
the C&A locomotive as imported was a 0-4-0 type, when modified it became 4-2-0.
This is also the designation for the next one in figure 13, while the next one from
1905 is 2-6-2.
SHIPS:

The first trials were made in France in 1775, but the power was insufficient. In 1783
another Frenchman ran a 182 ton paddle-wheel steamer upriver near Lyons. In
1787, one of several American experiments used the steam engine to drive an on-
board pump, the first example of water jet propulsion. In 1788, William Symington
constructed an engine to propel a boat on a lake near Dumfries in Scotland. In 1801,
he constructed an engine with a 56 cm double-acting piston to drive a tug boat. His
engine was without the cumbersome beam, but this was not followed up by his
successors.

The trials were successful, but were nevertheless stopped because of fear of damage
to the canal banks by excessive waves. The American Robert Fulton had seen
Symington's tests, and in 1807 - after previous experiments - achieved the first
commercial success with a steamer between New York and Albany. His ship used a
Boulton and Watt engine, and obtained a speed of 4 knots (7.4 km/h). Five years
later, there were 50 steam ships in the US. The first commercial success in Europe
was in 1812 on the river Clyde. The first war ship was built in 1814.
COMPANY PROFILE

About Vinayaga Boilers:

Vinayaga Engineering began manufacturing boilers in Establishment 2002. The

company CEO G. Vinayaga Perumal Managing Director,- P.Anbhuselvan,
As the demand for boilers grew, Vinayaga was soon in need of a larger facility. In
2002. Vinayaga broke ground for a new factory just south of Los Angeles in an area
where orange groves once stood. Just down the street was Downeys North
American Rockwell plant that built many of the Apollo spacecraft and another
company that made Apollo Motor Homes. In 2006, Vinayaga opened a second plant
in Puerto Rico to better serve East Coast customers. A few years later, the finished
interstate highway system made this plant obsolete and it closed.

Much has changed since then. The Apollo factory closed and became a movie studio.
The motor home facility now makes trolley tourist buses. One thing that hasn't
changed is that Vinayaga is still making boilers in Southern California. The reasons
for that can be found in these beliefs that shape our family owned business:

We believe our boilers and tanks should be built to last.

We believe boiler maintenance should be simple.
We believe in treating customers with respect.
We believe in helping boiler operators and owners understand our products.
We keep a file on every boiler we've ever built. We may know more about
your Vinayaga Boiler than you do.
We believe in research, development and long term testing.
 We recently moved to a new location in nearby Commerce, California. We
were fortunate to find a building twice as large as our former one and yet close
enough to retain all our employees. We have just completed a new R&D lab with
full boiler testing and demonstration capability. We have also added a machine shop
to enhance our manufacturing processes.

From our dependable steam and water boilers to our high efficiency Dura fins,
Vinayaga has boilers for almost every application and budget. Our dedicated
representatives throughout the United States and Canada offer strong local support
while our in-house tech service hot line is ready to answer any questions you might
have. We greatly appreciate your interest in Vinayaga and look forward to working
together.
MILESTONES:

Year Achievement

2005 Introduced Take-A-Part (Knockdown)

Boilers, Weatherproof Boilers, UL "A"
Labeled Boiler - Burner Packages,
Hinged Head plates.
Introduced Vinayaga Blow down Tanks
2006
and Condensate Return Tanks.
Shipped 1,100 Oil Fired Domestic Hot
2008
Water Heaters
First Durafin Boilers Ship.
2011

2014 Moved to NEW Location: 5832

Garfield Avenue, Commerce, CA
90040.
Mission and Vision:

Vinayaga Boiler Company manufactures the worlds largest Scotch marine

firetube boiler. Vinayaga pioneered the first water backed boiler over 15 years
ago and the first packaged boiler over 10 years ago. Vinayaga boilers are built
to last and carry the only 15-year warranty in the industry. In addition to the
quality and dependability, the conservative design provides excellent fuel to
steam efficiency resulting in the best life cycle costs in the industry.
Vinayaga also offers a full line of desecrators, surge tanks and blow down
heat recovery systems. These feed water systems are also designed and built
to a quality standard which allows us to offer a 10 year warranty, the only one
in the industry.
Vinayaga is well aware of the changing environmental requirements. While
our standard Vinayaga burners can attain less than 30 ppm , we know that
some regions of the United States are requiring emissions as low as 9 PPM.
High efficiency, availability and low emissions:

Vinayagais Boiler is recognized as one of the most innovative biomass boiler

suppliers in the world. We have a well-known and established reputation for
supplying biomass boilers and combustion systems with exceptionally high
efficiencies and availabilities, high fuel flexibility, and low emission impact.

Moreover, the systems have very low maintenance costs. The companys boiler and
combustion system concept is based on more than 30 years of hands-on experience
with steam generation and biomass combustion.
FUNCTIONAL DEPARTMENT

1. Production Department
2. HR Department
3. Finance Department
4. Marketing Department
5. Sales Department
6. Purchasing Department
ORGANIZATION CHAT
PRODUCTION DEPARTMENT

INTRODUCTION

Boilers have several strengths that have made them a common feature of buildings.
They have a long life, can achieve efficiencies up to 95% or greater, provide an
effective method of heating a building, and in the case of boiler steam systems,
require little or no pumping energy. However, fuel costs can be considerable, regular
maintenance is required, and if maintenance is delayed, repair can be costly.

Guidance for the construction, operation, and maintenance of boilers is provided

primarily by the ASME (American Society of Mechanical Engineers), which
produces the following resources:

Rules for construction of heating boilers, Boiler and Pressure Vessel Code,
Section IV-2007
Recommended rules for the care and operation of heating boilers, Boiler and
Pressure Vessel

Boilers are often one of the largest energy users in a building. For every year a boiler
system goes unattended, boiler costs can increase approximately 10% (1). Boiler
operation and maintenance is therefore a good place to start when looking for ways
to reduce energy use and save money.
Design and operation of Boilers:

A boiler is an enclosed vessel that provides a means for combustion heat to

be transferred into water until it becomes heated water or steam. The hot water or
steam under pressure is then usable for transferring the heat for the steam
requirements of Industries and for power generation. Combustion boilers are
designed to use the chemical energy in fuel to raise the energy content of water so
that it can be used for heating and power applications.

Many fossil and non-fossil fuels are fired in boilers, but the most common types of
fuel include coal, oil and natural gas. Previously, had oil fired boilers but due to the
high cost of operation, it has focused on only wood-husk fired boilers. During the
combustion process, oxygen reacts with carbon, hydrogen and other elements in the
fuel to produce a flame and hot combustion gases. As these gases are drawn through
the boiler, they cool as heat is transferred to water. Eventually the gases flow through
a stack and into the atmosphere. As long as fuel and air are both available to continue
the combustion process, heat will be generated.
Boilers are manufactured depending on the characteristics of the fuel, the specified
heating output, and the required emission controls.

COMPONENTS OF A BOILER SYSTEM

The main components in a boiler system are boiler feed water heaters,
deaerators, feed pump, economizer, super heater, attemperator, steam system,
condenser and condensate pump. In addition, there are sets of controls to monitor
water and steam flow, fuel flow, airflow and chemical treatment additions.

More broadly speaking, the boiler system comprises a feed water system,
steam system and fuels system. The feed water system provides water to the boiler
and regulates it automatically to meet the steam demand. Various valves provide
access for maintenance and repair.

The stem system collects and controls the steam produced in the boiler. Steam
is directed through a piping system to the point of use. Throughout the system, steam
pressure is regulated using valves and checked with steam pressure gauges. The fuel
system includes all equipment used to provide fuel to generate the necessary heat.
The equipment required in the fuel system depends on the type of fuel used in the
system.

Major Components Of Boiler:

Feed water system

Steam system
Condensate systems
Fuel system
1) Feed water system:

The water supplied to the boiler, which is converted into steam, is called Feed
water. The two sources of Feed water are condensate or condensed steam returned
from the process and makeup water (treated raw water) which must come from
outside the boiler room and plant processes.

Feed water heater

Boiler efficiency is improved by the extraction of waste heat from spent steam
to preheat the boiler Feed water. Heaters are shell and tube heat exchangers with the
Feed water on the tube side (inside) and steam on the shell side (outside). The heater
closest to the boiler receives the hottest steam. The condensed steam is recovered in
the heater drains and pumped forward to the heater immediately upstream, where its
heat value is combined with that of the steam for that heater. Ultimately the
condensate is returned to the condensate storage tank or condenser hot well.

Deaerators

Feed water often has oxygen dissolved in it at objectionable levels, which comes
from air in leakage from the condenser, pump seals, or from the condensate itself.
The oxygen is mechanically removed in a deaerator. Dearators function on the
principle that oxygen is decreasingly soluble as the temperature is raised. This is
done by passing a stream of steam through the Feed water. Deaerators are generally
a combination of spray and tray type. One problem with the control of deaerators is
ensuring sufficient temperature difference between the incoming water temperature
and the stripping steam. If the temperature is too close, not enough steam will be
available to strip the oxygen from the make-up water.

Economisers

Economisers are the last stage of the Feed water system. They are designed to
extract heat value from exhaust gases to heat the steam still further and
improve the efficiency of the boiler. They are simple finned tube heat
exchangers. Not all boilers have economizers. Usually they are found only on
water tube boilers using fossil fuel as an energy conservation measure.

A Feed water economizer reduces steam boiler fuel requirements by

transferring heat from the flue gas to incoming Feed water. By recovering
waste heat, an economiser can often reduce fuel requirements by 5 per cent to
10 per cent and pay for itself in less than two years.
A Feed water economiser is appropriate when insufficient heat transfer
surface exists within the boiler to remove combustion heat. Boilers that
 exceed 100 boiler hp, operating at pressures exceeding 75 psig or above, and
those that are significantly loaded all year long are excellent candidates for
economiser retrofit.

2) Steam system

Steam and mud drums

A boiler system consists of a steam drum and a mud drum. The steam drum is
the upper drum of a water tube boiler where the separation of water and steam
occurs. Feed water enters the boiler steam drum from the economizers or from the
feed water heater train if there is no economiser. The colder feed water helps create
the circulation in the boiler.

The steam outlet line normally takes off from this drum to a lower drum by a
set of riser and down comer tubes. The lower drum, called the mud drum, is a tank
at the bottom of the boiler that equalizes distribution of water to the generating tubes
and collects solids such as salts formed from hardness and silica or corrosion
products carried into the boiler.
 In the circulation process, the colder water, which is outside the heat transfer
area, sinks and enters the mud drum. The water is heated in the heat transfer tubes
to form steam. The steam water mixture is less dense than water and rises in the riser
tubes to the steam drum. The steam drum contains internal elements for feed water
entry, chemical injection, blow down removal, level control, and steam-water
separation. The steam bubbles disengage from the boiler water in the riser tubes and
steam flows out from the top of the drum through steam separators.

Boiler tubes

Boiler tubes are usually fabricated from high-strength carbon steel. The tubes
are welded to form a continuous sheet or wall of tubes. Often more than one bank of
tubes is used, with the bank closest to the heat sources providing the greatest share
of heat transfer. They will also tend to be the most susceptible to failure due to flow
problems or corrosion/ deposition problems.

Superheaters

The purpose of the super heater is to remove all moisture content from the
steam by raising the temperature of the steam above its saturation point. The steam
leaving the boiler is saturated, that is, it is in equilibrium with liquid water at the
boiler pressure (temperature).

The super heater adds energy to the exit steam of the boiler. It can be a single
bank or multiple banks or tubes either in a horizontal or vertical arrangement that is
suspended in the convective or radiation zone of the boiler. The added energy raises
the temperature and heat content of the steam above saturation point.

In the case of turbines, excessive moisture in the steam above saturation point.
In the case of turbines, excessive moisture in the steam can adversely affect the
efficiency and integrity of the turbine. Super-heated steam has a larger specific
volume as the amount of superheat increases. This necessitates larger diameter
pipelines to carry the same amount of steam. Due to temperatures, higher alloy steel
is used. It is important that the steam is of high purity and low moisture content so
that non-volatile substances do not build up in the superheater.

Attemperators

Attemperation is the primary means for controlling the degree of superheat in

a superheated boiler.

Attemperation is the process of partially de-superheating steam by the

controlled injection of water into the superheated steam flow. The degree of
superheat will depend on the steam load and the heat available, given the design of
the superheater. The degree of superheat of the final exiting steam is generally not
subject to wide variation because of the design of the downstream processes. In order
to achieve the proper control of superheat temperature an attemperator is used.

A direct contact attempaerator injects a stream of high purity water into the
superheated steam. It is usually located at the exit of the superheater, but may be
placed in an intermediate position. Usually, boiler feedwater is sued for
attemperation. The water must be free of non-volatile solids to prevent objectionable
buildup of solids in the main steam tubes and on turbine blades.
 Since attemperator water comes from the boiler feedwater, provision for it has
to be made in calculating flows. The calculation is based on heat balance. The total
enthalpy (heat content) of the final superheat steam must be the mass weighted sum
of the enthalpies of the initial superheat steam and the attemperation water.

3) Condensate systems

Although not a part of the boiler per se, condensate is usually returned to the
boiler as part of the feed water. Accordingly, one must take into account the amount
and quality of the condensate when calculating boiler treatment parameters. In a
complex steam distribution system there will be several components. These will
include heat exchangers, process equipment, flash tanks, and storage tanks. Heat
exchangers are the places in the system where steam is used to heat a process or air
by indirect contact. Shell and tube exchangers are the usual design, with steam
usually on the shell side. The steam enters as superheated or saturated and may leave
as superheated, saturated, or as liquid water, depending on the initial steam
conditions and the design load of the exchanger.
 Process equipment includes turbines whether used for equipment, air
compressors, or turbine pumps. Condensate tanks and pumps are major points for
oxygen to enter the condensate system and cause corrosion. These points should be
monitored closely for pH and oxygen ingress and proper condensate treatment
applied.

4) Fuel system

Fuel feed systems play a critical role in the performance of boilers. Their
primary functions include transferring the fuel into the boiler and distributing the
fuel within the boiler to promote uniform and complete combustion. The type of fuel
influences the operational features of a fuel system

The fuel feed system forms the most significant component of the boiler system.

Feed system for gaseous fuels

Gaseous fuels are relatively easy to transport and handle. Any pressure
difference will cause gas to flow, and most gaseous fuels mix easily with air.
Because on-site storage of gaseous fuel is typically not feasible, boilers must be
connected to a fuel source such as a natural gas pipeline. Flow of gaseous fuels
to a boiler can be precisely controlled using a variety of control systems. These
systems generally include automatic valves that meter gas flow through a burner
and into the boiler based on steam or hot water demand.

The purpose of the burner is to increase the stability of the flame over a wide
range of flow rates by creating a favourable condition for fuel ignition and
establishing aerodynamic conditions that ensure good mixing between the
 primary combustion air and the fuel. Burners are the central elements of an
effective combustion system.

Feed system for solid fuels

Solid fuels are much more difficult to handle than gaseous and liquid fuels.
Preparing the fuel for combustion is generally necessary and may involve
techniques such as crushing or shredding. Before combustion can occur, the
individual fuels particles must be transported from a storage area to the boiler.

Mechanical devices such as conveyors, augers, hoppers, slide gates, vibrators,

and blowers are often used for this purpose. The method selected depends
primarily on the size of the individual fuels particles and the properties and
characteristics of the fuel.

Stokers are commonly used to feed solid fuel particles such as crushed coal, TDF,
MSW, wood chips, and other forms of biomass into boilers. Mechanical stokers
evolved from the hand-fired boiler era and now include sophisticated
electromechanical components that respond rapidly to changes in steam demand.
PROCESS DESCRIPTION

The process starts off from the mixing of sodium silicate, china clay and salt.
These are then taken in a mixing tank in the required quantity and mixed thoroughly
into a homogenous mass. The basic raw materials of soap making are thus oil
containing FFA greater than 10%, caustic soda, steam, salt and scarp soap.

1).Crutcher

The crutcher is a vertical mixer used in the semi-boiled batch saponification, for the
neutralization of fatty acids with caustic soda and for the neutral fats saponification.

The crutcher is also used to add additives such as caoline, silicate and to color
the laundry soap in the drying plant.
Another use of the crutcher is the synthetic detergent soaps base production.
The crutcher can operate either at atmospheric pressure of pressurized.
The crutcher is provided with a vertical mixing worm placed inside a
containing tube which assures a strong mixing of the material to be processed.
2) The Dryer

Here, the continuous drying of the laundry soap takes place.

Neat Soap Filtration: The liquid soap is pumped through the soap filter into
the service tank.
Neat Soap Heating: The liquid soap is fed by the feeding pump into the heat
exchanger where it is heated at 80 to 90 degrees centigrade.
Drying: The heated liquid soap is atomized inside of the atomizer. The vapors
liberated inside (ones preformed inside heat exchanger and the ones flashed
off) are sucked away by the vacuum system. Soap that is sprayed on the wall
of the atomizer is, at this point dry, cold and solid. The spray dryer chamber
is at a pressure of 5-6mm of Hg. It is scrapped off the wall by action of rotary
scrappers. Scrapped soap falls on the worms of the plodder and is extruded
out in form of pellets or continuous bar.
 Soap Fines Separation and Recovery: The vapors containing the soap dusts
formed during spraying, are conveyed out of the atomizer through the
cyclones where they are separated from the dusts which falls on the bottom of
cyclones and is recovered.
Vapours Condensation: The vapors are condensed inside barometric
condenser. The vacuum pump produces and maintains the vacuum degree
inside the plant by removing all uncondensables.

Plodding and Extrusion: The dried soap is then forced out by a twin-worm
plodder through a perforated plate. The soap, coming out through the perforated
plate is cut into small pieces by a rotating knife cutter. The pieces are finally
extruded in the form of a bar through the nozzle plate of the specified
dimensions.
Packing: Here, stamping, wrapping and packing takes place which completes
the soap process.
 HR DEPARTMENT

OBJECTIVES HR DEPARTMENT

Attract, retain, develop, and remain effective and motivate human resource
with the required skills and competencies to meet organizational needs in tune
with changing business profiles and technological requirements.
Maintain good industrial relations with high level of employee for better
participation, productivity and quality at work.
To propagate, support and implement the principles of Global Compact.
Moving towards the concept of variable compensation it would be effective
by developing and implementing new schemes for performance related pay,
rewards and benefits in line with comparable organizations and employees
aspiration
 RECRUITMENT & SELECTION
Recruitment Policy:
Recruitment is based on the order issued by the government of India.
Reservation is made available for physically challenged, ex-servicemen,
schedule caste/tribes and other minorities.

Procedure for Recruitment:

VINAYAGA has developed a standard form of procedure:

1. Requisition form to employment exchange

 2. Call letter for selection
3. Call letter for trade/ technician Apprentices
4. Offer of training for trade/ technical apprentices Offer for temporary
employment.
5. Offer of appointment
6. Offer of appointment for supervisors
7. Acceptance form
8. Joining Report
9. Confirmation order for completion of probation

Source of Recruitment:

From employment exchange

From open market through advertisement in the press
By considering departmental candidates possessing the specified require
From reputed engineering/ management through college campus
interview

Selection:

In VINAYAGA, selection of applicants is done through the central

recruitment committee.
The committee constitutes of corporate personnel departments in
consultation with the respective division.
Human Resource Development Centre

Main functions of the HRD:

Identify the needs of employees.

Based on the need, training and development program is undertaken.
Training budget is approved by the HOD.
The required employees will undergo training.

TRAINING

Scope:

This is essentially limited to the product quality (that is general management,

behavioral management, technical and skill oriented programs).
Training for safety related aspects are given by the safely department and
for quality related by the quality department.

Responsibility:

The responsibility of identifying the training needs of all individuals lies with the
concerned controlling officers/HOD and group heads.

The responsibility of consolidating and listing, in the order of priority, the

programs to be conducted, in order to impart the necessary training lies the head of
HRDC
DEVELOPMENT PROGRAMMES:

Developmental programs are conducted for all categories of employees,

Executive, Supervisors and Artisans.
The company for this purpose invites faculty from outside.

COUNSELING PROGRAMMES:

Counseling programs are undertaken for employees who are

Irregular to work
Uninterested in the work, etc.

For this purpose, the company encourages suggestions, group work etc., and hence
motivate the employees.

PAY STRUCTURE:

Salary
Dearness Allowances.(DA)
House Rent Allowances.(HRA)
City Compensation Allowances.(CCA)
Reimbursement of Medical Expenses.
Traveling and Daily Allowances Rule.(TA)

Employee Benefits:

Leaves
Encashment Earned Leave. (EEL)
Leave Travel Concession. (LTC).
Group Saving Linked Insurance Scheme:
Group Saving Linked Insurance Scheme:

The VINAYAGA Group Saving Linked Insurance Scheme with effect

from April 2006 provides an insurance cover for all employees and promotes savings
to provide financial assistance to the employee/beneficiaries at the time of retirement
or insurance cover in the event of death while in service.

The other allowances include:

City compensatory allowances

Non practical allowances to medical
Late night snacks allowances for night shift employees
Messing allowances
Free uniforms accommodation
Free electricity
Kit allowances to employees deputed abroad
vehicle allowance
Welding allowance to high pressure welders
Transport subsidy, Traveling allowance
Convenience allowance to blind and physically handicapped employees,
Washing allowance , Educational assistance
Re-imbursement of tuition fees , Subsidiary to apprentices or trainees , Daily
allowance.
MARKETING DEPARTMENT

INTRODUCTION

Concept of Marketing:

Marketing can be described as any activity that is carried on with the specific purpose
of conveying information about the use, quality and value of a product or service in order to
promote or sell the product or service. Marketing is the way to announce the availability of a
commodity, service, idea or a brand to the world in such a way that people are interested in it and
wish to acquire it and use it. It serves the purpose of plugging the gap between the publics
requirement and the products that are available.

Aims of marketing department

Marketing involves a range of processes concerned with finding out what consumers want, and
then providing it for them. This involves four key elements, which are referred to as the 4P's. A
useful starting point therefore is to carry out market research to find out about customer
requirements in relation to the 4Ps.

The Four Ps

The Right The Right The Right

The Right
Price Place Promotions
Production
That 4Ps Are Following:
1. The Right Product
2. The Right Prize
3. The Right Place
4. The Right Promotions

The marketing department of any enterprise is responsible for promoting the products, ideas and
mission of the enterprise, finding new customers, and reminding existing customers that you are
in business. It organizes all the activities that are concerned with marketing and promotion. It may
consist of a single person or a group of people working in a hierarchal system who are responsible
for bringing the product of the business to the attention of its targeted customers. Since this
department is the key to your revenue and business activity, it requires people who have the skills
for dealing with people and understanding what they require.

There is no hard and fast rule to the organization of a marketing department, which depends
entirely upon the needs of the business, its size and the amount of money that it wants to spend on
marketing. But a typical marketing department in a large business operation is organized as
follows:

1. Marketing Manager: Marketing Manager works under the vice president marketing and
assists him with the implementation of all marketing strategies including creating messages
or advertisements for marketing, choosing the medium of displaying the messages, which
might include print media, television, banners and hoarding, website and social media
marketing, etc. A marketing manager is also responsible for managing the other employees
of the department. There may be one or several marketing managers depending upon the
size and requirements of the business.
2. Chief Marketing Officer: This is the person who is at the top of the pyramid and is in
charge of the marketing department. The responsibilities of CMO lie in the decision
making within the process of the development of the major marketing strategies, as well as
 running the marketing department. CMO is also answerable to the Board of Directors or
the Management about the results of the marketing strategies.
3. Marketing Director: The person in this role is responsible for all the marketing strategies
that are created and implemented. With his tasks he assists the CMO of the company.
4. Vice President Marketing: He is answerable to the Marketing Director. His responsibility
is the implementation of the marketing strategies of the organization. He works with the
marketing manager in determining the strategies, messages, and media to be employed for
marketing.
5. Marketing Analyst or Researchers: These individuals are responsible for research and
analysis that drives the marketing department and guides its marketing strategies by finding
out about the target customers and the competition of the business. Marketing Analysts
employ marketing tools such as surveys or studies to discover information that may be
useful for marketing. They report to the marketing manager.
6. Public Relations: Public Relation Officer is in charge of managing the reputation and
goodwill of the company. His job is to create understanding of the clients and try to
influence their thinking and behavior. PRO uses media management and communication
to build up the companys profile. The PRO works under the Marketing Manager and
reports to him.
7. Social Media Expert/Creative services: With the internet becoming a major player in
marketing, a company benefits from the services of Social Media Experts (SME) and
creative services. While the SMEs concentrate on marketing the business and its service
on the internet so that more people become aware of it, the creative services take care of
designing and presentation part of the business, these include websites, web pages,
brochures, booklets, flyers, advertisements, mailers and e-mailers, and all other
promotional material that is required by the marketing department. The creative services
and social media marketing report to the marketing manager and work under him.
8. Marketing Coordinator: Coordinates all the various sections of the marketing department
and manages the advertising and marketing campaigns. Marketing Coordinator is
responsible for tracking sales data, maintaining the promotional material inventory,
planning events, preparing reports, etc. They work with the Marketing Manager and assist
him.
 9. Marketing Assistant: Assists and reports to the marketing manager to run the day to day
business of a marketing department. Carries out administrative work required for the
smooth running of the department.

MARKETING MANAGERS:

Marketing managers are often responsible for influencing the level, timing, and
composition of customer demand. The role of a marketing manager can vary significantly based
on a company's size, corporate culture, and industry context. For example, in a
large consumer products company, the marketing manager may act as the overall general manager
of his or her assigned product. To create an effective, cost-efficient marketing management
strategy, firms must possess a detailed, objective understanding of their own business and the
market in which they operate. In analyzing these issues, the discipline of marketing management
often overlaps with the related discipline of strategic planning.
Activities of Marketing Managers:

1. Focus on the Customer.

2. Monitor the Competition.

3. Own the Brand.

4. Find & Direct Outside Vendors.

5. Create New Ideas.

6. Communicate Internally.

7. Manage a Budget

8. Set the Strategy, Plan the Attack, and Execute

1) Focus on the Customer

Marketers should spend time listening to their customers (and prospective customers) in order to
understand their needs and wants regarding a particular product or service. Soliciting thoughts and
input from internal stakeholders such as Sales and Customer Service is also appropriate, as these
departments are typically closest to the customer.

2) Monitor the Competition.

Learning about, and understanding the competitive landscape is also an important function of the
Marketing Department. Marketers should be the go to people within an organization to answer
the following types of questions: Who is the competition (both direct and indirect)? What do they
communicate? Which customers do they serve? Why do customers choose the competitor versus
you?
3) Own the Brand.

The perceptions and feelings formed about an organization, its products / services, and its
performance is what is known as its brand. The Marketing Department is responsible for creating
meaningful messages through words, ideas, images, and names that deliver upon the promises /
benefits an organization wishes to make with its customers. Furthermore, the Marketing
Department is responsible for ensuring that messages and images are delivered consistently, by
every member of the organization.

4) Find & Direct Outside Vendors.

Internal Marketing Departments do not create magic alone. Therefore, Marketing needs to source
and oversee a group of outside resources (a.k.a. partners) such as copywriters, graphic designers,
web designers, database specialists, and printers so that a company can get the most bang from
its marketing efforts.

5) Create New Ideas.

Whether its customer acquisition campaigns, keep-in-touch programs, new product promotions,
retention efforts, or something in between, the Marketing Department should ultimately be
responsible for developing new ideas that generate revenue for the company. This does not mean
that the Marketers have to come up with every idea on their own; however, they need to identify,
cultivate, and work with others (see point #4) to execute programs that will create revenue.

6) Communicate Internally.

It is important that the Marketing Department communicates with all departments inside an
organization. Since any employee (regardless of position) can support (or damage) a brand, value
proposition or even specific program initiatives, the Marketing Department needs to take
responsibility for disseminating information throughout the organization (this includes internal
education and training when appropriate).
7) Manage a Budget.

Establishing and communicating messages to the marketplace costs money. Therefore, Marketing
Departments should be responsible for estimating the anticipated expenditures associated with
marketing activities. Once set, Marketers should be held responsible for meeting all budget
projections.

8) Set the Strategy, Plan the Attack, and Execute.

One of the key activities for a Marketing Department is to integrate an organizations goals,
strengths, channels of distribution, competitive environment, target markets, pricing, core
messages, and products into one cohesive document known as the Marketing Strategy. As part of
the strategy, the Marketing Department should also develop the list of tactical ideas such as direct
mail, print advertising, and search engine optimization that will enable the organization to
communicate its message to customers and prospects. With a strategy and tactical ideas in hand,
the Marketing Department is now ready to take on the responsibility of executing the programs
and initiatives to drive sales and revenue for the organization.

Market research:

The marketing department will usually combine both forms of research. The marketing
department will seek to make sure that the company has a marketing focus in everything
that it does. It will work very closely with production to make sure that new and existing
product development is tied in closely with the needs and expectations of customers.

Modern market focused organizations will seek to find out what their customers want. For
example, financial service organisations will want to find out about what sort of accounts
customers want to open and the standard of service they expect to get. Retailers like Argos
and Homebase will seek to find out about customer preferences for store layouts and the
range of goods on offer. Airlines will find out about the levels of comfort that customers
desire and the special treatment that they prefer to receive.
 There are two main types of market research:

a. Quantitative: Research involves collecting a lot of information by using

techniques such as questionnaires and other forms of survey.
b. Qualitative: Research involves working with smaller samples of consumers, often
asking them to discuss products and services while researchers take notes about
what they have to say.
MARKETING PROCESS AND FUNCTION:
Market Research:
Marketing research is the systematic investigation of the facts relevant to various aspects
in marketing. It helps in identifying the needs of the customers. It involves study of the markets
and customers, their tastes and preferences, and what they are willing to buy, when they are likely
to buy, etc.
Marketing planning:

Marketing plans are prepared to achieve marketing objectives of an organization.

Product Planning and Development:

PPD is concerned with identifying customers needs, developing new products and
improving existing products in order to meet desires of customers.
Buying and Assembling:
Buying is the purchase of raw materials for use in manufacture of finished goods for
resale. Assembling is the collection of specific type of products from different buyers under a
common roof.

Standardization and Grading:

Standardization refers to the process of setting certain norms or standards for a product
with regard to shape, size, color, quantity, quality, weight, etc. It helps in ensuring that products
confirm to standards. Grading refers to the process of classification of products into different
categories on the basis of quality, size, etc. Grading is generally done for agricultural products,
such as fruits and vegetables. Graded products are of uniform quality and become easy to market.
Branding:
A brand is a name, sign, symbol, or design assigned to a product so as to differentiate
it from products of competitors.

Packaging:

Packaging is the act of designing and producing the package for a product. A package
is a wrapper or container in which a product is kept.

Customer Support Services:

In today's competitive environment, customer support services play an important

role in marketing. Services such as after sale services, maintenance services, and handling
customer complaints provide satisfaction to customers and also helps in building product loyalty.

Promotion:
Promotion refers to communication used to inform, persuade, and influence the
prospective customers to buy a product.

Physical Distribution:
Is concerned with making the goods and services available at the right place. It
includes 2 important decisions:
Channels of Distribution are middleman or intermediaries like wholesaler, agents, and
retailers that facilitate the movement of goods and services and their title between the point
of production and the point of consumption, by performing various marketing activities.
Physical movement of goods from producers to consumers through means of transport,
storage and warehousing, and inventory control.

IMPORTANCE OF A MARKETING DEPARTMENT

The Marketing Department is the key to good marketing and sales. It promotes and establishes a
business in its niche, based on the products or services the business is offering. It identifies the
areas in which the product fits and where the business should focus its marketing strategy and,
therefore, spend its budget for the maximum coverage and results. The marketing department helps
a business to do the following:

Build relationship with the audience: Creates awareness of the business and its products
as well as provide inputs that create interest for the audience. It brings in new customers and
creates new business opportunities for the enterprise.
Involve the customer: It engages existing customers, tries to understand them and hear what
they have to say. It monitors the competition, creates new ideas, identifies outlets, plans the
strategy to involve customers and retain them.
Generate income: Finally, the aim of the marketing department is to generate revenue. All
its activities are aimed at broadening the customer base and finding opportunities that would
create more revenue for the enterprise.

FINANCE DEPARTMENT

INTRODUCTION
 Finance is the most important department in the organization. It plays very important role
in the organization. Finance is the life blood of each and every business. Management of
financing is planning and controlling of firms financial resource.
The finance officer occupies a key position. He is one of the dynamic members of the top
management key, and his role day by day is becoming more intensive and significant in
solving the complex management problems.
The Finance Department is subdivided into three departments as under.
A. Accounts Department
B. Cane Accounts Department
C. Cost and Audit Department

ACCOUNTS DEPARTMENT:
Deals with day to day financial activities of maintaining accounts i.e. entry of day
to day transactions, issue of cheque, preparing Trial Balance, Profit and Loss Account, Balance
Sheet, maintaining Bank Accounts, Cash Management, Purchase and Sales Accounts. The books
ofaccount maintained by the company are:
1) Sales records: Sales records are maintained for each of the sold s and other product.
2) Purchase Records: Purchase records are maintained for the purchase of various items.
3) Expenses Records: The records are maintained for the purpose to make entry for various
expenses incurred in a particular period of time.
4) Stock Records: Stock records are maintained to know the levels of stock of various items for
the particular period of time .These are both in terms of rupees and units.
5) Budgets: A budget provides an easy method of continuous monitoring of activities of the
organization. A master budget, which takes into, accounts all activities of an organization.

Following are the budgets prepared:

i. Budget Profit and Loss A/C.
ii. Budget Trading A/C.
iii. Budget Fund Flow Statement.
iv. Budget Balance Sheet.
v. Sales Budget.
 vi. Cash Budget.
vii. Expenses Budget.

CANE ACCOUNT DEPARTMENT:

Deals with the farmers in purchasing cane and making time to time payment, advance payment,
transporting, maintaining the detail information through Weigh Bridge Department about weight
of the cane while it comes to the factory, maintaining daily report like Crushing Report, Bagging
Report, Baggasse and other material like Trash, Ash, , Chemicals and other raw material in and
out.
Cost and Audit Department: The functions of Cost and Audit Department:
1. The internal audition of various areas of each and every department including revenue and
expenditure side.
2. Cost Accounting work of U.S.W. Ltd. Products like , rectified spirit, denatured spirit, power and
Indian made liquor product.
3. Periodical physical checking of following departments about their inventory books of accounts
of the stores, time keeper office etc.
4. Preparation of additional data feedback for management audit committee or any other
department required.
5. Special audit of various departments like Agriculture Department, Account Department, Time
Keeper Office, R & D Department, Civil Construction Projects, Cane Purchase Department Etc.
6. Checking of Closing Stock Statement.
7. Suggesting remedial actions in case of increased cost.
The software package used in finance department is Tally and Own Created software by the IT
Department.
PRIMARY FUNCTIONS OF FINANCE DEPARTMEN:
Maintain a general accounting system
Collect all taxes and revenues
Invest cash reserves
Prepare financial reports
Administer the payroll
Procure equipment and supplies and control inventories

THE FINANCE DEPARTMENT IS COMPRISED OF THREE DIVISIONS:

i. Administration
ii. Financial Operations
iii. Financial Planning

ADMINISTRATION
The Finance Administration Division is responsible for the overall direction and policy
implementation. It is also responsible for coordination of the Finance Department, which includes
budgeting, accounting, purchasing and treasury functions. The Finance Administration Division
provides financial advice to the company.

FINANCIAL OPERATIONS
The Financial Operations Division includes the Accounting Section which maintains the
accounting system, the payroll system, the fixed asset system, reconciles accounts, and prepares
various financial reports. The Treasury Section provides centralized cashiering, collection, and
accounting for improvement district bonds, collects for all business licenses, collects all
receivables, and audits various tax sources for compliance.
FINANCIAL PLANNING
The Financial Planning Division includes preparation and administration of the Annual Budget,
completes special research projects as assigned by the Manager and Council. The Purchasing
function of the Financial Planning Division procures all services, supplies, and equipment for all
departments of the Company, and surpluses items no longer needed by the Company.

BASIS FOR PREPARATION OF FINANCIAL STATEMENT:

a) The financial statement have been prepared in compliance with all materials aspects
of the mandatory, accounting standards issued by the institute of chartered
accountants of India and the relevant act, 1956.
b) Consent with revenues recognized and expenses accounted for on their accrual.
Fixed asset:
a) Fixed asset stated at cost, net if excise and custom duty where Moved credit on capital
goods is availed except fixed assets taken over as a result of nationalization, which are
stated at values then approved by the board and revalue price less accumulated depreciation
and impairment loss, if any.
b) Cost includes freight and insurance duties and taxes, installation and commissioning
charges and other charges the date of commissioning. In case of imported fixed asset, it
includes in addition above, other charges payable as per foreign exchange contract.
Investment:
a) Long term investments are stated at the cost of acquisition. However provisions for
diminution are made to recognize a decline, other than temporary in the value of
long-term investment.
b) Current investments are stated at the lower of cost or fair market value.
Foreign exchange transactions:
Foreign currency transactions in respect of non-monetary items like fixed asset,
inventories and investments in equity shares etc are recorded at the exchange rate
prevailing on the date of transactions. In respect to the monetary items of assets and
liabilities like cash receivable, payable etc are translated on reporting data at closing rate
 or at a fixed rate where exchange rate is booked in advance. Exchange rate difference
during the year is recognized in P&L account.

Use of estimates: Preparation of financial statements requires estimates and assumptions to be

made that affect the reported amount of assets and liabilities on the date if financial statement and
the reported amount of revenues and expenses during the reporting period. Difference between the
actual results and the estimates are recognized in the period in which results are
known/materialized.

Provisions and contingent liabilities and contingent assets: Provisions involving substantial
degree of estimation in measurement are recognized obligation as a result of past events and its
probable that there will be an out flow of resources. Contingent liabilities are not recognized but
are disclosed in the note. Contingent assets are neither recognized nor disclosed in the financial
statements.

Earnings per share: Basic earnings per equity share are computed by dividing net profit after tax
by the weighted average number of equity shares outstanding during the year. Diluted earnings per
equity share are compute by dividing adjusted net profit after tax by the aggregate of weighted
average number of equity shares and diluted potential equity shares outstanding during the year.

PURCHASE DEPARTMENT
INTRODUCTION
This department accepts the requisitions from the different departments, in which the
material needed, quality and quantity is mentioned. They have the vendors list and they ask
quotations from them. Finally after receiving the quotation they place the order to
appropriate vendor. The purchase order has four copies. From that one has sent to Accounts
Department, one to the Vendor, one to the department from which the requisition is
received and last is retained with them selves for reference. This department work
according to the Just In Time method. Means it does not blocks the funds of the company.

Purchase Department does not place orders for capital goods. It deals with the materials,
which are necessary to run day-to-day activities of production, stationary material etc.

This department uses the software developed by their IT department from FoxPro for
keeping records and placing orders. Also they use the other windows programs like Ms-
for documentation.

Why Purchasing Management Is So Important:

Purchasing management is no longer seen as 'just a part' of logistics or
marketing, but as strategic factor in the entire organization. According to the recent
research production companies purchase nowadays approximately 70% of their turnover,
service companies purchase approximately 40% of their turnover. While many companies
understand the importance of purchasing and its strategic impact on the whole organization,
purchasing process still requires a more intensive management.
Actual Purchasing Management Problems:
In many companies and organizations, the purchasing process goes hand in
hand with moundsof paperwork, faxes and even handwritten ordering sheets. Managers
waste a lot of time on data searching and transmitting, status meetings, reminding each
other about important tasks, personal conversations for delegating tasks to employees and
controlling them, manually creating reported.
EFFECTIVE PURCHASING MANAGEMENT SOLUTIONS
Nowadays to stop wasting time and money, and to provide the right product, at the
right price, at the right place and at the right time, a head of purchasing department
needs a possibility to manage all information and communication flows in a real
time mode, including purchasing planning, execution, tracking and reporting. A
team leader needs a system that provides a total control on Purchasing Management
Process, Supplier Management Process and all purchasing teams work at a lowest
operational level, supports discovering of hidden bottlenecks and fruitless costs,
finding new sources of added value and so on.
To manage purchasing process and tasks effectively a head of purchasing
department and his/her team needs not only to be a professional and create a team's
motivation from achieved results but also to have at his/her disposal a Powerful
centralized purchasing data and task management system.

Advanced companies have already understood it and implemented a purchasing

data and task management on the basis of appropriate software. It gives them new
possibilities to drill down into organization of purchasing process details and find
new sources of additional strategic advantages such as time and cost at a lowest
operational level. Now it's time to benchmark their best practice for all
organizations. Download purchasing task management software right now.
SUPPORT SERVICES CAN BE PROVIDED FOR SUCH MAJOR FIELDS
1. Maintenance and support of the computers and peripherals: Bunch of periodical
operations which should be fulfilled for normal computer functionality: hardware testing,
monitoring, upgrading, making daily data back-ups and reports.

2. Communication technical services: Maintaining the informational infrastructure: Local

Area Networks and Wide Area Networks (LAN/WAN), ensuring data communications and
telephone systems.
3. Software solutions: Development, procurement, installation, maintenance and support of
the various software applications.
4. Office and enterprise systems: Development, procurement, installation, maintenance and
support of the main business software systems data, documents, payrolls etc.
management, accountancy software, Internet Web site and so on.
5. Informational security: Establishing of informational security policy, installing, setting
and maintenance of anti-malware and anti-intrusion systems (firewalls, anti-viruses, etc.).

FUNCTIONS OF A PURCHASING DEPARTMENT:

Most major companies and even some government organizations have a purchasing or
procurement department as part of everyday operations. These departments provide a service that
is the backbone of many manufacturing, retail, military and other industrial organizations. Many
individuals, even some who work for these companies, are unaware of what the purchasing
department does, why it exists or what purposes it serves. To understand better what the role of
the purchasing department is, consider some functions it performs.

Procuring Materials:
One role of the purchasing department is to procure all necessary materials needed for
production or daily operation of the company or government organization. For a manufacturing
company, this might include raw materials such as iron, steel, aluminum or plastics, but it also
might include tools, machinery, delivery trucks or even the office supplies needed for the
secretaries and sales team. In a retail environment, the purchasing department makes sure there is
always sufficient product on the shelves or in the warehouses to keep the customers happy and
keep the store well-stocked. With a small business, it is especially important to keep inventory
ordering at a reasonable level; investing large amounts of capital in excess stock could result in
storage problems and in a shortage of capital for other expenditures such as advertising or research
and development. Purchasing also oversees all of the vendors that supply a company with the items
it needs to operate properly.

Evaluating Price:
A purchasing department also is charged with continuously evaluating whether it is
receiving these materials at the best possible price in order to maximize profitability. This can be
challenging for a small business that may purchase in lesser quantities than a larger vendor and
which thus may not receive the same type of bulk discounts. A purchasing department in a small
business needs to shop around to find the best vendors at the most reasonable prices for the
company's particular size orders. Purchasing department staff may communicate with alternate
vendors, negotiate better pricing for bulk orders or investigate the possibility of procuring cheaper
materials from alternative sources as part of their daily activities.

Paperwork and Accounting:

Purchasing departments handle all of the paperwork involved with purchasing and
delivery of supplies and materials. Purchasing ensures timely delivery of materials from vendors,
generates and tracks purchase orders and works alongside the receiving department and the
accounts payable department to ensure that promised deliveries were received in full and are being
paid for on time. In a small business, this means working closely with the accounting department
to ensure that there is sufficient capital to buy the items purchased and that cash is flowing
smoothly and all payments are made on time.

Policy Compliance:
The purchasing department also must ensure that it is complying with all company
policies. For example, in a small business, individual staff members may communicate with the
purchasing department about purchasing needs for things such as office supplies or computers.
Before making a purchase, the purchasing department must ensure that it heeds the proper
protocols for purchase and budget approval and must ensure that any items are purchased in
accordance with the overall purchasing policy of the organization.

SALES DEPARTMENT

Purposes of sales organization

1. To permit the development of specialist.

2. To assure that all necessary activities are performed.
3. To achieve coordination or balance.
4. To define authority.

SALES ANALYSIS:

Because the basic purpose of a sales organization is to generate sales, sales analysis
is an obvious and important element of evaluating sales organization effectiveness. The difficulty
however is to determining exactly what should be analyzed. One key consideration is in defining
what is by a sale. Definitions include a placed order, a shipped order, and a paid order, defining a
sale by when an order is shipped is probably most common. Regardless of the definition used, the
sales organization must be consistent and develop an information system to track sales based on
whatever sales definition is used. Another consideration is whether to focus on sales dollars or
sales unit this can be extremely important during times spanning price increase or when sales
people have substantial latitude in negotiating selling prices.

We can sub divide the sales analysis in different categories.

1. Organization Level of Analysis.

2. Type of sales.
3. Type of analysis
 1) ORGANIZATIONAL LEVEL OF ANALYSIS

Sales analysis should be performed for all levels in the organization for two basic
reasons First sales managers needs at each level sales analysis at their level and the next level
below for evaluation and control purposes. For example, a regional sales manager should have
sales analyses for all regions as well as for all districts within his or her region this makes it possible
to assess the sales effectiveness of the region and to determine sales contribution of each district.
Second, a useful way to identify problem areas in achieving sales effectiveness is to perform a
hierarchical sales analysis, which consists of evaluating sales results throughout the sales
organization from a top-down perspective essentially the analysis begins with total sales for the
sales organization and proceeds through each successively lower level in the sales organization.

2) TYPES OF SALES

It is usually desirable to evaluate several type of sale such as by the following categories.

1. Product type or specific products.

2. Account type or specific account.
3. Type of distribution method.
4. Order size.

The analysis of different types of sales at different organization levels increases management
ability to detect and define problem areas in sales performance. However, incorporating different
sales types into the analysis complicates the evaluation process and requires an information system
capable of providing sales data concerning the desired breakdowns.

3) TYPE OF ANALYSIS
The discussion to this point as focus on the actual sales results for different organizational
levels and type of sales however the use of actual sales results limit the analysis to
comparison across organizational level or sales type these with in organizational
 comparison provide some useful information but are insufficient evaluation of sales
effectiveness.
Comparing actual sales with sales results with sales forecasts and quotas is extremely
revealing. A sales forecast represents an expected level of firm sales for defined products,
markets, and time periods for a specified strategy. Based on this definition a sales forecast
provide a basis for establishing a specific sales quota and the reasonable sales objective for
a territory And effectiveness index can be computed by dividing actual sales results by the
sales quota and multiplying by hundred. The sales effectiveness makes it easy to compare
directly the sales effectiveness of different organizational levels and different type of sales.
Another type of useful analysis is the comparison of actual results to previous periods. This
type of analysis is used to determine the sales growth rate for different organizational levels
and for different sales type.
A final type of analysis to be considered is a comparison of actual sales results to those
achieved by competitors this type of analysis is used to determine the sales growth ratefor
different organizational levels and for different sales type.

COST ANALYSIS

A second major element in the evaluation of the sales organization of sales organization
effectiveness is cost analysis. The emphasis here is on assessing the costs incurred by the
sales organization to generate the achieve level of sales the general approach is to compare
 the cost incurred with planned costs as defined by selling budgets. Corporate resource
earmarked for personal selling expenses for a designated period represent the total selling
budget.
Selling budgets are developed at all level of the sales organization and for all key
expenditure categories. Both the total expenditure for each of these categories and sales
management budget responsibility must be determined. Sales management budget
responsibility depends on the degree of centralization or decentralization in the sales
organization. Although there is no perfect way to arrive at these expenditure levels, two
approaches warrant attention
1. Percentage of sales method
2. Objective and task method

1) PERCENTAGE OF SALES METHOD:

The percentage of sales method calculates an expenditure level for each category by
multiplying an expenditure percentage times forecasted sales. The effectiveness of the percentage
of sales method depends on the accuracy of sales forecasts and the appropriateness of the
expenditure percentage. If the sales forecasts are not accurate, the selling budget will be incorrect,
regardless of the expenditure percentages used. If the sales forecasts are accurate, the key is
determining the expenditure percentage. This percentage may be derived from historical spending
patterns or industry averages. Sales management should adjust the percentage up or down to reflect
the unique aspects of their sales organization.

2) OBJECTIVE AND TASK METHOD

It is a type of zero based budgeting. In essence, each sales manager prepare a separate
budget request that stipulates the objective to be achieved, the task required to achieve these
objective, and the costs associated with performing the necessary tasks.

RESPONSIBILITIES OF SALES DEPARMENT:

Small businesses often organize their sales and marketing operations differently than larger
businesses, putting more of an emphasis on sales until they have sufficient capital and staff to
elevate the marketing function. Understanding what responsibilities a sales and marketing division
will need to handle until you more formally separate these areas will help you maximize your
resources to boost your sales and profits.

1. Goal-Setting: The sales and marketing division sets individual sales rep quotas, as
well as the overall volume goal for the company. To achieve sales goals, it creates bonus
and commissions structures. The division uses past sales figures and expert projections to
estimate which products will sell where and in what amounts.

2. Product, Pricing and Distribution Planning: Because sales and marketing managers
spend much of their time talking directly to customers, they guide the development of
products and services. They recommend modifying or dropping products or services or
adding new ones to the companys mix, based on what customers want. A sales and
marketing department has the responsibility for deciding where the company should sell
and what its prices should be. This includes choosing which, if any, intermediaries the
company will use, such as wholesalers, distributors or retailers. This requires the division
to research where the companys competitors are selling and where its customers say they
want to shop.

3. Customer Service: To maintain its customer base, sales and marketing takes
responsibility for making sure buyers are happy, as well as trying to upsell them. The
division is proactive in contacting customers with surveys and special offers and is reactive
in attempting to solve any problems that might cause the company to lose customers.

4. Promotions: The word promotions covers a broad array of sales and marketing efforts,
including advertising, social media, public relations, sales, event sponsorship, cause
marketing, discounts, loyalty programs, rebates, trade show appearances and buyers clubs.
The sales and marketing team decides which publications to advertise in, which TV, radio
or websites are best for promoting the companys products or services, and what contests,
giveaways, discounts or other marketing methods will help it boost sales.
SCOPES OF THE STUDY

Scope means how many uses for completing this report space. The scopes are given bellow-

Factory

Buying House

Discussion

Internet

Some of our senior brothers can help us.

I can collect information various books and relevant paper what related with apparel
industry.
SWOT ANALYSIS

STRENGTHS

1. Strong engineering base and stable industrial relationship

2. Has been making profits continuously and paying dividends since 2005

3. Great support from the collaborators has helped it to acquire modern technology and transform
it to suit Indian conditions

4. Huge customer base in domestic business leading to major presence and influence in the market

5. More than 190 products and 30+ major product groups

6. Ability to deliver high quality products at a competitive price

WEAKNESSES:

1. Inability to provide to give suppliers credit, soft loans and financing of power projects.

2. Longer delivery cycles when compared with other international competitors.

3. The company lacks effective marketing infrastructure.

OPPORTUNITIES:

1. There is a huge demand of power and is expected to grow further

2.Ageing power plants need more service and spare parts
3. As it cost competitive, it has potential export opportunities
THREATS:

1. Increased competition both national and international companies

2. Foreign competitors rapidly spending on promotion tactics

3. Consolidations in the industry have reduced the turnover of the company

LIMITATION OF STUDY
There were some limitations in conducting the organization study at Vinayaga Boiler Pvt Ltd.
Those are Following

1. There were difficulties in obtaining data from executives and managers due to their busy
work schedule.
2. An in-depth study of the company could not be carried out due to shortage of time.
3. The reliability of data used for study is largely depends upon the companies reports and
the information given by executives.
4. The company has the limitation to disclose their financial details, so a detailed analysis of
financial performance of the company is not possible.

SUGGESTION

A proper training should be given to the employees and the workers to

enhance their skills to increase their productivity and ultimately of the
company.
 The management should make the market survey time to time to get more and
latest information about the market factors like the price, demand, current
consumer trends etc.

As the world has become a global village, the management should have the
latest knowledge and informations about the world because now a little
change in any corner of the world can affect your business.

The top management should give the autonomy and the flexibility to every
manage to make decisions according to the situation at any time and in the
absence of the top managers.

All the duties and responsibilities of the employees and the workers should be
clearly defined.

The computer technology should also be used in decision making as well as

in storing and feeding the data.

The company should make it possible to deliver the goods to the buyers at the
agreed time.

CONCLUSION

The study had confirmed that the company is having a good Screening process. From this
study, it is found that majority of the workers screen the candidates effectively by
understanding clearly about the requirements and properly match the profile. Suggestions
given in the report may be implemented for the benefit of the workers and the company.

The company may conduct similar type of research at regular intervals to know the
changing attitude of workers and to know about their effectiveness to improve the
Screening process. The system is designed to provide complete satisfaction to the user. The
operation of this system is good in its response time.
 The survey after implementation of the project and support team has shown how far the
project is useful to the customer. The survey shows that maximum of the customer use the
portal effectively and usefully. Regarding the support team the customer has given a good
opinion and they have rated the team high in all aspects like training, supervision, code of
conduct and in all other areas.

REFERENCE

1. Capehart, B., Turner, W. and Kennedy, W., 2006. Guide to Energy Management.
2. ASHRAE Handbook, HVAC Systems and Equipment, 2008.
3. Boiler and Heaters, Improving Energy Efficiency, Canadian Industry Program for Energy
Conservation, August 2001.
4. Federal Energy Management Program Fact Sheet, PNNL, January 2005.
5. FEMP O&M Best Practices, a Guide to Achieving Operational Efficiency, U.S. Department of
Energy, August 2010. http://www1.eere.energy.gov/femp/pdfs/omguide_complete.pdf
6. Efficient Boiler Operations Sourcebook, Fourth Edition, F. William Payne and Richard E.
Thompson, 1996.
7. The Control of Boilers, 2nd Edition, Sam G. Dukelow, 1991.