Documente Academic
Documente Profesional
Documente Cultură
Submitted to
Mr. A.N. Pandey
Manger(Training)
BPCL Naini
Submitted by
Rachit Sharma
VT/105/B.Tech/ME/15
I.E.T Lucknow
Acknowledgment
I would like to humbly express my sincere thanks and gratitude to
Mr.A.N.Pandey (manager-training) for their proper guidance and
support throughout my training. Without their proper cooperation,
motivation, inspiration support it would not have been possible to be a
part of B.P.C.L and have amazing experience of newer technologies and
innovations related pumps and compressors.
I am thankful to Mr. P.G. Chaudhary (DGM PEX),
Mr. S.C. Mishra (Sr. Manager W.S.), Mr. Ganesh Ji Singh(DGM PCP
FDR), Mr. R.K. Sahi (Dr. Manager QCM),and to all the worker and
employees of BPCL those who given their valuable time and helped me
in each state.
Rachit Sharma
VT/105/B.Tech/ME/15
I.E.T Lucknow
About BPCL
Bharat Pumps and Compressors Ltd. (BPCL) (A Public Sector
Undertaking under the control of Ministry of Heavy Industries & Public
Enterprises, Govt. of India), was set up in the year 1970 at Naini,
Allahabad as an import substitution unit for manufacture of
sophisticated process pumps and compressors for core sector industries,
which were hitherto being imported by them. The company is engaged
in manufacture and supply of heavy duty pumps & compressors and
high pressure seamless and CNG gas cylinders / cascades to cater the
needs of oil exploration & exploitation, refineries, petro-chemicals,
chemicals, fertilizer and downstream industries.
Vision
To become an Indian MNC in the field of fluid handling, Gas
Compression, gas storage Equipment, services and project management
Mission
To provide quality products and services to core sector industries with
especial thrust on Oil and natural Gas, Petrochemicals, Refineries,
Nuclear and thermal power plants, Fertilizers and Public Transport
Services complying to health and safety norms.
IV.
PAST PERFORMANCE
Sl.No
1.
2.
3.
4.
5.
Parameter
Value of
production
Value
Added
Net
Profit/(loss)
After Tax
Net Worth
No. Of
Employees
2000-01 01-02
5950
6643
02-03
6441
03-04
4750
04-05
7000
3044
2589
2793
2422
3483
559
1246
1292
2494
1086
5413
1583
6759
1522
8470
1376
11340
1257
12161
1244
Parameters
1.
Value of
production
Value added
Net
profit/(loss)
Net worth
4750
7000
10318
47.4%
2422
2494
3483
1086
4959
184
42.4%
Turnaround
11340
12161
11715
No. Of
employees
1257
1244
1233
3.7%
improvement
Reduction of
11 employees
2.
3.
4.
5.
Production
Value
Added
Net
3483
4959
6146
23.9%
1086
184
1914
940%
Profit/(loss)
Net worth
12161
Became
positive
No. Of
1244
1233
1214
Reduction
5.
employees
of 19
employees
BPCL Certified for Integrated Management Systems in
Dec.2006,by M/s QS Services Zurich(Switzerland) i.e., ISO
9000/14001 & OHSAS 18001
Proposal for strengthening & financial restructuring of
BPCL approved by Cabinet in December , 2006
Deregistered from BIFR in February 2007
Measures such asi. Smart Card Punching System
ii. Uniform to all Employees
iii. Canteen Up gradation
iv. Jatropha Plantation taken at Plant
Model of excellence introduced ABHAY MODEL of
EXCELLENCE a copy right of CMD,BPCL
Vendor base widened
4.
11715
+5695
PRODUCTS OF
1.
BPCL
Centrifugal Pump
Maximum Power
Maximum pressure
Maximum capacity
Fluids handled
1700 KW
675 kg/cm2
315 M3/Hr
Drilling mud, cementing slurry,
crude oil steam,condensate,Heavy
Water, fatty acids ,ammonia etc.
2. Reciprocating Pump
Maximum Power
Maximum pressure
Maximum capacity
Fluids handled
2500 KW
140 kg/cm2
12000 M3/Hr
Demineralised water, sea
water,hydrocarbons,neptha,LPG,carbo
nate Solution, Alkaline and acidic
Solution, Ammonia liquor and slurry
2. Reciprocating Compressors
Maximum Power
Maximum pressure
Maximum capacity
Fluids handled
25000 KW
450
70000
Air, nitrogen ,oxygen ,carbon
dioxide, hydrocarbons ,ammonia,
synthesis gas ,hydrogen
sulphate ,coal gas etc.
4.Ammonia Carbamate
5.Cementing unit pumps
6.Sucker Rod Pumps
7.High Presuure Industrial Gas Cylinders
Maximum pressure
Maximum capacity
Fluids handled
400
110
Oxygen,
nitrogen ,hydrogen ,argon ,air ,heli
um, carbon di-oxide ,nitrous
oxide ,acetylene ,ammonia,
chlorine ,Freon , LPG ,compressed
natural gas(CNG)
COLLABORATORS OF
BPCL
1. International:
Lavan Refinery, Tehran(Iran)
ONGC
Bharat Oman Refiner Ltd.
CPCL
Numaligarh Refinery
Oil India Limited.
Bongaigaon Refinery Petrochemicals Ltd.
2. NUCLEAR POWER
Department of atomic energy
Operation:
It is a boring machine in which job are placed on table having jaws to
fix the job. Tools are clamped over column with rams (having 3 rams)
that can be given cross and vertical feed. Two handles are provided for
vertical and cross travel. Distance travelled is indicated over DRO
which show digital readings for cross and vertical feed.
Tool Used: Insert tools made of carbide are used that are usually of
rectangular shape.
2. HORIZONTAL BORER
There are many types of horizontal borers having same functions, tool
used and operations but different specifications .Available borers are:
Horizontal Borer(SM-210)
Horizontal Borer(WD-160)
Horizontal Borer(BFT-125)
Horizontal Borer(AZ-11)
Operation:
On the Horizontal Borer m/c, job is clamp on a fixed table and table
moves in rotary motion at its axis which is horizontal. It has headstock,
tailstock & supporting column cross slide, table and its parts. In the
headstock on the Horizontal spindle of m/c, boring or milling tools are
clamped. Headstock can be adjusted horizontally. A motor is used to
drive spindle. Headstock has devices for different spindle speed and
feed. Head stock can be moved up & down. Long boring rods are
clamped with head stock spindle and end supporting column. Table is
BFT-125:
Operations:
Job is kept over the base which can revolve about the vertical axis. The
rpm is controlled via switches having gear according to the colour code
selected like R, G, Y, B with a separate switch for neutral adjust.
Control panel include handles for cross feed, vertical feed, threading
and for on off. It get power for ram movement via hydraulic
pressure.DRO is used to detect the cross and vertical feed.
Functions that can be performed are:
1. Facing
2. Turning
5. Grooving
etc.
Tools used: Tools made of mild steel, HSS, HCS, CS, Cast steel are
used.
8. CYLINDRICAL GRINDER
Specifications:
9.HONNING MACHINE
Operations: Honing is a grinding process done to get finished surface of
job like cylinder hole, internal surface. In this process, honing stores are
used as tool made with the help of bonded abrasives. This process is
made on machined surface. Making rotary & reversed motion to tool
process is made. In this process 0.1 to 0.25 mm metal can be cut. There
are two honing m/c:
2. TP-5
Specification:
30 tools can be used.
This CNC m/c cost around 15 Crores bought from Juaristi Spain
and could perform all operations except grinding.
G-M Code is used.
Operation: This m/c is also CNC which can perform all operations
except grinding. G-M Code is used here also. Four jobs can be
performed simultaneously .One job is operated over 4 phase.
3.MP-7
This CNC m/c cost around 25 Crores bought from Juaristi Spain.
60 tools can be used.
G-M Code is used.
Specifications, operation, job, tools used are same as TP-5.
Height: 1200 mm
Bed length: 450 mm
Effective length: 1000 mm
Table width: 350 mm
Table travel: 450 mm
Vertical Travel: 500 mm
9.TURRET LATHE:
All operations except tapering which can be done using chase die only,
tool used are same as centre lathe. It has 6 different job holding sites in
hexagon head and 4 in carriage which enable mass production.
HEAT TREATMENT:
Heat treatment is done to improve certain properties of parts to be used
in pumps and compressors. Properties such as Ultimate tensile Strength,
BHN value, Impact value are varied. Ex: 302 BHN is required in pump
shaft or head shaft or transition shaft.
TYPES OF FURNANCES:
1) Muffle furnace: 50 KW power
2) Therlac furnace: 36 KW power
3) F.A.C furnace
4) Mar Tempering furnace
5) Nitriding furnace
6) Small pit furnace
7) Big pit furnace
GRINDER MACHINE
1) Horizontal Grinder:
Size: 500X25 mm
Power: 5 HP
Max.speed: 1450 rpm
2)Drill Point Grinder: It is used for to make the drill sharp. It can be
used to sharp drill having two, three or more No. Flutes. It is high
speed grinder made of AlO3.
3)Horizontal surface grinder: It can be used to clean plane surface with
a magnetic base.
4)Universal tool & cutter grinding machine: It can be used grind internal,
external and cylindrical surface. A wheel make of SiC is used
when solid material is being grinded e.g. brass, a wheel made of
AlO3 is used for grinding at high speed.
SLOTTING MACHINE
They are used for making groves, key ways and slot ways. They make
use of quick return mechanism. A slotter uses return 2:1, a planer 5:3, a
shaper 3:2.
Motor power : 22 KW
G-M Code is used in software.
Job: Walnut part of RP pumps part.
9. KEYWAY MACHINE:
Job: Taper lock bush used in mud pump
Function: Vertical cutting for making keyway
Tools used: HS bead, high bead steel
10. CNC VERTICAL TURNING LATHE (CNC-VT-510):
Specifications:
FABRICATION SHOP
There are two welding processes performed in this shop i.e.:
Electric Arc Welding: Acetylene and oxygen gases are used which
are controlled through double stage regulator. Two dial are there
for stock pressure and allowed pressure. In this process fusion of
parent metal and addition of metal through a consumable electrode
is done.
TIG Welding: In this mild steel is used as a filler metal with copper
coating. Electrode of tungsten is used. There are different types of
filler rod available:
MS rods
Code
7018
7018
6013
Diameters
3.15
4
4
QCX (QUALITYCONTROL)
For manufacturing of pumps, compressors or any other part customer
and manufacturer i.e. BPC decide the quality plan so as to ensure
required quality of the component manufactured. Different test are done
to check the quality such as:
Radiography
Assembly test
Hydro and Air test
Measurement of job is done in the Standard Room and quality check of
machined part is done in m/c shop inspection room.
RADIOGRAPHY:
It is a non destructive test through which internal defects occurring
during the processes of casting and welding are determined.
Defects in casing are misrun, shrinkage, porosity whereas defects in
welding are crack, lack of penetration, lack of fusion, slag inclusion,
undercut and embrittlement.
This test is performed through two methods:
1) X-RAYS
2) Y- RAYS
X-RAYS:
X-rays are generated using anode and cathode rod. We can increase
penetration by increasing voltage. It is panoramic i.e. rays spreads in
3600 direction. Two machines are there in use:
Name
Power,current Penetration Focal point
Andrex 160kV,5mA 10 mm
2 mm
Sheffered 300kV,5mA 40 mm
4.5 mm
Manufac. country
Indian
German
QUALITY PLAN
Quality plan is decided through consultation of vendor, manufacturer
and costumer .Some deviation that occur after the manufacturing is
consulted to costumer for its compatibility. Ex- Plate used for the frame
is taken through chemical analysis, Charpy V-test ,Tensile test and
crankshaft is taken through chemical, ultrasonic, mechanical properties
i.e. BHN, dimension check, surface crack checking through dye
penetration exam & fluid end through hydro test etc.
STANDARD ROOM
Different tools are here to get accurate and precise measurement and fit.
Allowances and tolerances are marked before and after machining.
Some of the tools are Vernier calliper, Micrometer, Bevel Angle
protector, Dial bore gauge, Sine bar etc.
WORKSHOP QUALITY
Customer either by self or elect a third party to witness and decide
quality plan with the manufacturer. Production dept. Decide the
processes to be done and construct a process chart. Testing of quality is
done before and after the machining. Different card are there with red ,
yellow and green colour to dictate the fault.
Capacit
y in
m3/hr
Up to
1500
Head
in m
Temp
Range
Application
No. of
sizes
avail.
Petrochemical,refineries 47
,thermal and nuclear
power stations and for
handling high temp,
petro products and
cryogenic liquid. Very
low NPSH application
Max. Suction Pressure :
38 Kg/cm2
Up to
350
-1900C
to
+4500C
Up to
1500
Up to
350
-1900C
to
+4500C
300 to
15000
20 to
140
-200C to
+1500C
Cooling water
35
circulation, irrigation
water supply, crude oil ,
Boiler Feed Water,
Booster service etc.
500 to
6000
150 to
400
-200C to
+1500C
Long distance
transportation of liquid
14
stage supported on
bearings at either
end with double
suction impeller
Horizontal, Axially
split double volute
multistage with
centre line support
and opposed
impellers
arrangement.
or petroleum products
through pipelines.
40 to
1000
150 to
1400
-1200C
to
+2050C
Up to
2400
Up to
65
Up to
1400C
15 to
6400
Up to
870
-2000C
to
+2200C
8.
-2000C
to
+2200C
9.
VN
Up to
1000C
5.
DVM
X
6.
LC
7.
VB/V
Horizontal single
stage foot mounted
back pullout with
broad passage vane
type or channel
type(non-clogging)
impeller
Vertical submerged
type multistage
with/without Barrel
bottom suction
pumps.
vertical, single
stage, volute type
with zero leakage
sealing provision
100 to
600
40 to
100
10
RECIPROCATING PUMPS:
There are two types of reciprocating pumps:
Crankshaft assembly
Diaphragm assembly
External assembly
internal assembly
2) PLUNGER PUMP:
Available models are: D323ST, A334, A336, A344, A356, 63-10R
where first alphabet is for model type, 2nd for triplex(3) or doublex (2),
3rd for plunger size and 4th for stroke length [applied for the above A
series models ]
There are many types of assembly involved such as:
Power end assembly
Stuffing box assembly
Crankshaft &pinion
lubricator assembly
RECIPROCATING COMPRESSORS
Most of the working is same as RP. Some important parts & assembly
are: piping accessories Frame assly. Slide body gear pump
Crankshaft assly. Connecting rod assly. Crosshead Flywheel
slide shield assly. Suction valve with/without unloading fork pump
control box Heat exchanger Instrumentation & control
WORKSHOP SERVICES
This department is concerned with the maintenance of the machines.
There are two types of failures/faults:
Mechanical fault:
Usually include belt breakdown; gear fault in gear box of centre, turret
and capston lathe; bearing fault. There are different types of bearing
such as needle roller bearing use to bear heavy load, thrust bearing for
axial load, ball bearing, cylindrical roller bearing used in cranes and
roller bearing. Specifications of bearing include size, property, outer
diameter, inner diameter and thickness.
If teeth of gear are damaged they are repaired. First the damaged teeth
are cut down through milling m/c then machining is done over it.
Afterward heat treatment is done to incur desired properties.
Electrical fault:
This includes fault in electrical panel, motor burnout etc.
CNC machines by themselves display the fault occurred with the
location. In other machines we have to identify the location of fault
occurred
Different steps are taken such as repairing, overhauling or
replacement.
Usually there are heavy and costly machines so repairing is usually
done.
Overhauling is done once in the lifetime service of a machine.
Preventive maintenance such as lubrication, primary cleansing
operation in machines is done weekly.
Backup components are there so that whole manufacturing process
does not get affected with the failure.
PRODUCT RANGE
Product
Name
High Pressure
Industrial
Seamless Gas
Cylinder
CNG On-Board
Cylinders
CNG Cascades
20 to 200 Litres.
Water Capacity
1000 litres. to
4500 litres.
water capacity
-
Product
view
Specification
Range
Up to 62 Litres.
Water Capacity
Diamete 140 mm to 232 mm
r
Material C-Mn alloy Steel
Filling
Pr.
Workin
g Pr.
Code
150 Kg / Cm2
232 mm to 406
mm
CR-MO alloy
Steel
204 kg/Cm2
250 Kg/Cm2
340 kg/Cm2
435 Kg/Cm2
IS 15490: 2004
CR-MO alloy
Steel
255 kg/Cm2
MANUFACTURING FACILITY
BPCL is having manufacturing capacity of 45,000 cylinders per year
which can be extended to 60,000 cylinders per year. Our workshop is
equipped with all the latest machines in order to give production of
45,000 cylinders per year. Few of them are named below:
Sl.
No.
1.
4.
CNC
Hot
Spinning
Machines
Induction Heating Furnace
Bottom Forming Hydraulic
Press
Hardening Furnace
5.
Tempering Furnace
6.
7.
8.
9.
10.
Hydro
stretch
Equipment
11.
Air
Leakage
testing
Equipment
Shot Blasting Machine
Painting Booth
2.
3
12.
13.
Testing
432 mm size
400 T
1750 mm long cylindrical(Max
Temp 1000C)
1750 mm long cylindrical(Max
Temp 800C)
80 mm
7500 mm L x 2500 mm W x 2100
mm H
7500 mm L x 2500 mm W x 2100
mm H
7500 mm L x 2500 mm W x 2100
mm H
Diameter 120-275 mm, Length
600-1600 mm, Normal working
pressure 350 Kg/Cm2
Pressure 210 Kg/Cm2, Cap. 410
M3 /hr.
Upto 300 mm Diameter Job
100 Cylinders per shift
CUSTOMERS
Sl.
No.
1.
2.
3.
Product
Customers
High Pressure
Cylinders
Gas filled
Oxygen
Carbon Dioxide
hydrogen
Medical O2
Helium
Argon
Colour on cylinder
Black
White half band on black
Red
White full band on black
Middle brown
Peacock blue
7.
8.
9.
10.
N2 O
Air
N2
CNG
French Blue
French gray
Black full band on French gray
Red full band on white