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Vocational Training Report

(Observation Based Training)

BHARAT PUMPS &


COMPRESSORS
LIMITED
(A government of India Enterprise)
Naini, Allahabad
Uttar Pradesh, India-211010

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.

Bharat Pumps and compressors Ltd.,Naini ,Allahabad is a Certified


Integrated management Systems Company having ISO 9001:2000,ISO
14001:2004,OHSAS 18001:1999 includes environment , occupational
health & safety management systems, with the objective to
design ,manufacture and supply capital goods in the fluid handling field
including provision of services connected therewith .BPC caters to the
need of core sectors of the company such as oil exploration and
exploitation ,refineries, petro-chemicals, chemicals and fertilizers,
process industries and power plants and indigenously designs and

manufactures heavy duty centrifugal pumps, reciprocating compressors


and high pressure seamless gas cylinders and other hi tech oil field
equipments such as cementing units sucker rod pumps etc.
BPC is the only company in Asia to manufacture a wide range of hitech products, heavy duty pumps and compressors and high pressure
seamless and welded gas cylinders, under one roof.
Bharat Pumps & Compressors Ltd., A Govt. of India Undertaking
under Department of Heavy Industries & Public Enterprise is pioneer in
gas cylinder manufacturing and company is having a proven track
record of manufacturing cylinders for more than 40 years. It is worth
mentioning that BPC is the first company which has indigenously
designed, developed and manufactured the very first Industrial cylinder,
CNG On-board cylinder and CNG Cascade in India thereby substituting
import. We have capability and capacity to manufacture cylinders to
comply with any international standards.
BPCL Industrial cylinders range are for various gas applications like
permanent gases such as Oxygen, Air, Argon, Helium, Hydrogen,
Nitrogen, and liquefiable gases such as Carbon-di-oxide and Nitrous
Oxide etc. in conformation with IS 7285 Part-II-2004, Gas cylinder
rule and Chief Controller of Explosives. BPCL also provide BIS test
certificates and filling permissions along with the cylinders.
Up on of Govt. Of India initiative of pollution free environment, the
company started the manufacturing of CNG cylinders and CNG
Cascades from 1995 to facilitate use of CNG as an alternative fuel. BPC
is the only public sector company having in-house infrastructure to
manufacture CNG cylinders and cascades both to cater needs of various
city gas distribution projects, automobile industries and retrofitters. it is
worth mentioning that BPC is the first pioneer company who has
indigenously designed, developed and manufacture the very first CNG
cascade thereby substituting import.

Turnaround History of BPCL


Through sheer corporate strategy and employee motivation, Bharat Pumps &
Compressors Ltd. has pulled itself back from the brink of closure.

Scenario Till 2004-05 & Root Cause For Sickness


Bpcl was a sick company having suffered losses consistently since
inception aggregating to 175.29 crores. The net worth of the
company as on 31.05.2005 was negative at 121.61 crores.
As on March 2005, the company had manpower of 1244 employees.
The employees also lost the zeal to work required for productive results
as the Company could not generate enough production & obtain orders
to maintain even a working business cycle. Bharat Pumps &
Compressors Ltd., as such was on verge of closure with minimal
production and failure in securing orders in competitive biddings.
The root cause for sickness was delay in meeting the commitment with
respect to delivery of equipment to costumers, which resulted into
1.Low level of production
2.High manpower cost
3.Fluctuating or low level of order book
4.High manpower cost
5.Low employee productivity.
The weak-spots of the organisation, which added to sickness, along with
above aspects were:
I. Design & Technology
No influx of talents & virtually nonexistent Product
Development /Research & development
Low level of computerization & design software usage

No up gradation of product knowledge by the executives


No efforts for joint working with customers & suppliers for
improvement in technology & design methodology
II.

Materials Management & Stores

A clerical Production Planning & Control Department


Bureaucratic Purchase Management, fearful to take risk &
busy in avoiding audit queries
Poor relations with suppliers
No fresh vendors
Absence of vendor rating system, reliance on few selected
vendors
High Conversion time between Indent to Purchase Order
III.

Marketing, Computerization & After Sales Service

Product centric & Manager centric marketing in place of


customer centric
Poor customer relations
Delay in response to offers
Poor after sales service
Delayed response to site complaints
Erection & Commissioning Department at loggerheads with
Marketing & Production
Same marketing strategy for two different business of Pumps
& Compressors and Gas Cylinders

IV.

Human Development & Communication

A divided lot, no unity of purpose


Casteism, Regionalism
Political interference
Workers/Unions divided on caste lines & political affinities
Narrow selfish interest of leaders
Promotions based on personal loyalties/caste, less on
contributions or merit
No emphasis on training & development
No encouragement to attend conferences or presentation of
papers
Top Management focus more on production less on cost &
quality
Few efficient officers over burdened, without credits
Negative , un-cooperative attitudes
Poor image in local community
Inability to punish offenders & undisciplined
Rivalry among officers

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

The Turnaround In The Year 2005-06


The moment of Pride and Recognition came for BPCL in 2005-06.The
special efforts and corporate strategies put in place during the last
quarter, after joining of present incumbent on 31.12.2005 have yielded
the much awaited turnaround of the company which was on the verge of
being closed on account of losses since its inception in 1970 for about
35 years as the Company had an accumulated loss of 175.29 Crs till
2004-05.the turnaround in less than a year from near closure/winding up
situation has been made possible through dedicated and sustained
pursuits of revival strategies and following the fundamental concepts of
excellence with emphasis on participative management.
BPCL achieved a net profit of
1.80 crores during financial Year
2005-06 after accounting for Govt. interest amounting to
13.50
crores as against a loss of 10.86 crores during previous year 200405.this remarkable feat of turnaround is more significance since it has
been achieved without considering the benefits of financial restructuring
or any Govt. Assistance.
SALIENT ACHIVEMENT IN 2005-06
Sl.No

Parameters

2003-04 2004-05 2005-06 %change


over last year

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.

BPCL, now known as My BPC to employees and this was made


visible to all through suitable Boards at the entrance of the plant.
A quarterly meeting/address to all employees together to share
urgent issues/achievements.
For the first time in the last 35 years, the Chief Executive started
staying in a township by the side of the Plant at Naini, instead of
accommodation at faraway place at Allahabad
Vision document prepared for 10 years
Smile meetings to end the tug of war between the HODs
Initiative on MAATI SE SONA
Improvement in communication
Overall improvement through 5S initiative and cost savings to the
tune of 40.00 lakhs
Capacity utilisation improved to 43% from 29%
Further, energized by the performance and achievement of 2005-06,
the Company targeted to achieve turnover of
135 Crs in 200607 and net profit of 16.3 crores, however, with dedicated and
missionary efforts, the performance has been historical and
turnover achieved is 144 crores and net profit is at 19.14
crores a growth of 53% in turnover and 940% in net profit.

SALIENT ACHIEVEMENTS 2006-07


Sl.No
Parameters 200-05 2005-06 2006-07 %growth
Over last
year
Value of
7000
10318
14983
45.2%
1.
2.
3.

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

Doubles turnover in two years-breakthrough progress


in 2007-08
During the year 2007-08 BPCL achieved astounding historic
performance with sales growth of 207% over 2005-06 & achieving
profits for three consecutive years from a level of profit of 184 lakhs
in 2005-06 to 21385 lakhs in 2007-08,BPCL was accredited with
API-7k monogram.

Bpcl defies the economic meltdown & registers


growth of 21% during 2008-09
BPC achieved the turnover of 236.36 crores in 2008-09 @net profit of
26.86 crores. The company has entered into export market by
obtaining the breakthrough order from M/s Lavan Refinery Iran for
supply of 6 Nos. Compressors worth
48 crores.
It is pertinent to mention here that BPC have achieved the value of
production of 15348 lakhs in 2006-07, which was not projected even up
to 2009-10 by consultant.
The performance in the year 2009-10 has been highest ever at level of
turnover of 27112 Lakhs & PBT of
4122 lakhs.
The corporate philosophy to implement the approach of Total Quality
Management (TQM) and Integrated Management System (IMS) in
order to achieve and sustain a reputation for quality at a Competitive
Cost in National & International markets for BPCL products and
services through collective involvement of all was initiated.

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

BPC has absorbed technology from following renowned manufacturers


through technology transfer collaboration.
BPC collaborators had vast experience in the field of rotating equipment
and BPC has absorbed technology for execution of orders for its
complete range products and their engineering division has been
regularly upgrading the tech and design to meet upgraded, international
code requirement (API, ASTM).These are as follow:
1. Pompes Guinard , France
2. Oil Well , USA
3. Nuovo Pignone , Italy
4. URACA , Germany
5. B.J. Hughes, USA
6. Rom Consultant, Romania
7. Showa Koatsu , Japan

CLEINTS OF BPCL PRODUCTS


BPCL caters to the needs of core sectors by offering products/services
to meet their specific requirements. Major core sectors BPCL serve are:

1. International:
Lavan Refinery, Tehran(Iran)

1. National Oil and Gas Sector:


IOCL
HPCL
Bharat Petroleum Corporation Ltd.

ONGC
Bharat Oman Refiner Ltd.
CPCL
Numaligarh Refinery
Oil India Limited.
Bongaigaon Refinery Petrochemicals Ltd.

2. NUCLEAR POWER
Department of atomic energy

Nuclear Power Corporation Ltd.


Bhabha Atomic Research

4.FERTILIZERS AND CHEMICALS

Hindustan Fertilizers Corporation Ltd.


Mangalore Chemicals & fertilizers.
Indian Farmers and fertilizers corporation
Rashtriya Chemicals & fertilizers
Indo-Gulf fertilizer & Chemicals
National fertilizers Ltd.

Gujarat State fertilizer Corporation.

PUMPS &COMPRESSOR PLANT(P.C.P)

BAY-1 (HEAVY MACHINE SHOP)


PCP Bay 1 include heavy machines such as Vertical boring machine,
Horizontal boring machine, Plano mill ,Vertical turret, Vertical
lathe ,Centre lathe, Radial drill, cylindrical grinder and honing machine
usually done on large jobs for heavy operations with high precision and
accuracy. Parts of reciprocating pump, centrifugal pump, reciprocating
compressor undergo machining operation are then assembled in
PCM.Many spare parts are also machined as per the order.
1.Vertical borer (VB-2500)

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.

Job: Discharge elbows boring etc.


Specification:

Table diameter : 2400 mm


Vertical travel : 1500 mm
Cross travel : 1400 mm
Safe load : 10000 Kg
Value : 22 lakhs

Functions such as facing, drilling and boring are primarily done on


this machine.

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

moved horizontally and tangentially with respect to bed by power feed


with job. On the operating box there are various buttons for operating
such as on ,off, spindle movement, ram movement, base movement,
column movement, high speed on, active on pressing, hand feed etc.
In m/c shop BAY-1 these are the Horizontal Borer with specifications:
WD-160:

Spindle diameter : 160 mm


Arm travel: 1250 mm
Vertical travel: 2500 mm
Longitudinal travel: 3000 mm
Safe load: 10000 Kg
Cost: 28.7 lakhs

BFT-125:

Spindle diameter: 125 mm


Cross travel: 1600 mm
Vertical travel: 1048 mm
Longitudinal travel: 2000 mm
Maximum boring diameter: 800 mm
Boring depth: 1120 mm
Max. Height of job: 1040 mm
Distance from plate to side rest: 2700 mm
Safe load: 3000 Kg
Cost: 8.5 lakhs

Cutting oil is used for lubrication.

JOB: horizontal drilling in discharge elbow etc.


Usually drilling is done vertically, since in discharge elbow we have
to drill in sideways therefore we use horizontal borer.

3.PLANO MILL (PM-1600)


Operation: surface cleaning from top and sideways. Machine operates at
1600 rpm.

Tool used: insert of triangular shape made of HSS is used.


Job: Planning operation over fluid in used in mud pump.

4.VERTICAL TURRET (VTL-1425)


Specification:
Table diameter: 1425 mm
Job height: 1600 mm
Vertical travel (Cross rail): 750 mm
Turret travel: 650 mm
Value: 8 lakhs

Tools used: Insert tool, brazing tool, white bead (HSS)


Job: Turning operation on piston ring etc.
Operations:
It is a turret type boring m/c in which table moves round its vertical axis.
Job moves around clamp with jaws. Tools are clamped on turret head
and positioned at working area .Turret is on a cross rail which can be
moved up & down, right and left with the help of power cross rail and
can be position at any height on the frame. The m/c is also known as
vertical turret m/c. Gear and heavy wheel can be made on it.

5. VERTICAL LATHE (CVTL-150)


Specification: Base Diameter-1500 mm, No. Of rams-1

Tools used: Tools made of carbide are generally used.


Job: Turning, facing and grooving operation on fluid end which is a part
of reciprocating pump.

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

3. Step turning 4. Taper turning

etc.

6. CENTRE LATHE (LC-1000)


Specifications:
Centre distance: 6500 mm
Swing: 1000 mm
Safe load: 10000 Kg
Value: 8 lakhs

Tools used: Tools made of mild steel, HSS, HCS, CS, Cast steel are
used.

Operations: Various operations are done such as:


1. Facing 2.Turning 3.Step turning 4.Taper turning 5.Drilling

6. Boring 7.Reaming 8.Knurling 9.Grooving 10.Undercutting


11. Threading 12.Chamfering

Job: Facing, turning and chamfering operation on coupling used in


locomotives.

7.RADIAL DRILLING MACHINE


Operations:
The main part of the m/c is the radial arm on which spindle driven
mechanism is attached on parallel ways. Spindle driven mechanism can
be round up to 3600 at a pillar & also can be made to move up and down.
It can be set up at any position on the radial arm;this radial arm can be
set at any angle according to our need this radial arm has a system to be
set at any height on the vertical pillar with the help of radial drilling m/c
drilling is made easy on heavy jobs. The size of this machine is
expressed with its radial arm length. The radial arm is to be near about 3
meters. On radial drilling shaping, backing etc can be done. Drilling tool
used is called Drill .It has two types:
Tapered shank drill
Parallel shank drill
Tapered shank drill is used with socket but parallel shank used with Jaw
chuck .Cutting oil is used as cutting material with water. For Al
kerosene oil is used.

Job: Drilling on fluid end which is a part of reciprocating pump.


Tools used: Tool made of HSS is used.
Specifications:
Radial drill (DR-8)
1) Drilling capacity : 75-80 mm

2) Vertical travel : 1050 mm


3) Arm length : 2700 mm
4) Spindle RPM : 11.2 to 1000
5) Feed : 0.035 to 0.56 mm/rev
6) Cost : 2.8 Lakhs
Radial drill (RF-51)
1) Drilling capacity : 100 mm
2) Vertical travel : 1200 mm
3) Arm length : 3000 mm
4) Cost : 4.8 lakhs

8. CYLINDRICAL GRINDER
Specifications:

Distance between centre : 3000 mm


Max Swing : 630 mm
Wheel size : 750 x 100 x 30.5 mm
Auto feed of wheel head: 0.005mm/0.05mm
Speed of work head : 1425 mm
Long movement of table : 50 to 3460 mm/min
Max weight of job :1200 Kg
Max speed: 7 mm/min
Cost: 7 lakhs

Features: Main features of cylindrical grinder are as follow:


Rotary motion of the job
Rotary motion of the wheel
Speed / motion of the job w.r.t wheel
Motion of the wheel w.r.t job

Parts: Base, Table, Headstock , Tailstock, Wheel & Cross feed.

Operation: Cylindrical grinder is used for grinding simple cylindrical


parts. But it is used for grinding process like taper grinding face and
shoulder grinding, fillet grinding.

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:

1. SMALL HONNING M/C: In this m/c 32 mm to 300 mm bore diameter.


Its accuracy is 0.4 mm and height is 120 mm.

2.BIG HONNING M/C: In this m.c,75 mm to 650 mm bore diameter can


be made to honing .Its height is up to 24 mm and accuracy is as above.
For cooling, coconut and kerosene oil are used in 1:20 ratio.

BAY 2(LIGHT MACHINE SHOP)


1.CYLINDRICAL GRINDER (C.N.C)
Parts:
1)Headstock 2)Tailstock 3)Support 4)Steady rest 5)Touch probe 6)
Coolant supply 7)Grinder 8)Wheel balancing sensor

Operations: Usually shafts surface finishing is done on this m/c. Shaft


rest upon supports on both sides and over steady rest to avoid sagging
(Steady rest are provided so that error due to bending can be
neglected).Commands are given in computer using G-M Code .Two
directions X &Z are allotted for grinder wheel movement & bed/shaft

movement respectively. Distances are given in microns .Many buttons


are provided for various purpose such as grinding spindle
speed(manually),feeding of grinding/shaft depend on selection of X, Z,
Jog input, Auto etc.

Tool Used: Grinding wheel consist of Silica, Aluminium etc is used as a


tool.

Job: Surface finishing of Nuclear Shaft is done.


Specifications:
Carrier Speed: 50 rpm
Grinding Speed: 700 rpm
Power system: Hydraulic Power Pack-servo system 68,Pnematic
system

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.

Job: All operations related to Barrel are done.


Tools Used: Insert (manufactured through Casting) and ceramic
materials are used as tools.

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.

4.CENTER LATHE (NH-22):


Bed length: 3m
Chuck diameter: 450 mm
Speed: 40 to 2040 rpm
Gear system:
1)First Gear System has gear having teeth 30,72,30,60,30
2) Second gear system has gear having teeth 60,72,60,30

5. CENTER LATHE (ENTERPRISE 1550):


Chuck diameter: 450mm
Bed length: 1000 mm

6. HORIZONTAL MILLING MACHINE (FN 2U):

Height: 1200 mm
Bed length: 450 mm
Effective length: 1000 mm
Table width: 350 mm
Table travel: 450 mm
Vertical Travel: 500 mm

Cuter diameter: 2000 mm

7. HORIZONTAL BORER : BH100,WHN 130,CBH 100


All operations, tool used, type of job to be handled and specification are
same to the horizontal borer of Bay-1.

8.VERTICAL TURRET (VTL):


Same as the Vertical turret in Bay-1.

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.

PROCESS: Type of heat treatment process depends upon following


factors:
1) Type of material to be processed
2) Requirement: Level on properties to be inherited.
3) Quenching medium: oil quenching, air quenching ex. carbon steel
& alloy steel are quenched in oil & air respectively.
4) tempering

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

JOBS: Heat treatment of tri-rod, case wearing, impeller wearing up to


1200 0C.Soaking time is 2 hr for 1 inch

BAY 4 & BAY 5


MILLING MACHINES:
1) Vertical Milling Machine:
Max speed: 45 to 1800 RPM
Table feed: 500 mm
Motor type: 3 phase motor

Operations: Facing, drilling, gear cutting, multiple cutting.


2) Horizontal Milling Machine:
Movement:
Horizontal movement (X-direction)-550 mm
Cross movement (Y-direction)-350 mm
Vertical movement (Z-direction)-350 mm
Speed: 35.5 to 1800 rpm
Feed: 16 mm/min to 800 mm/min

Operation: facing, slot cutting, sheeting(cutting in to


pieces),angular cutting, dovetail cutting, concave & convex
cutting, gear cutting

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.

1. JIG BORING MACHINE:


It is also used. It can perform all operations. But since it accuracy is
affected by rough usage, it is used selectively.

2. CNC LATHE (SBCNC-60 & SBCNC-402D):


Specification:

Maximum swing diameter over bed: 800 mm


Maximum turning diameter between centres: 600 mm
Spindle speed: 12-2000 rpm
Number of tools: 12

Motor power : 22 KW
G-M Code is used in software.
Job: Walnut part of RP pumps part.

6. 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.

7. CAPSTON LATHE:All operations, tool used are same as centre lathe.


It has 6 different job holding sites in tailstock which enable mass
production.

8. THREAD ROLLING: This machine is used to provide threading using


thread roller without any material loss. This ensures high strength to
the component. Ex- threading in connecting rod, piston rod in
compressor.

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:

Maximum swing diameter/turning diameter: 2000/1700 mm


Table diameter: 1600 mm
Travel axis: X=1000 mm Z=1400 mm
Cross section of ram = 210*210 sq mm
Load on table = 7000 Kg

Power of table drive= 30 KW

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

CUTTING M/C (BEND SAW):


In this machine processes like milling, cutting are performed. Tool used
is steel teeth made by hardening. Job like cutting of muff coupling is
done.

PROFILE GAS CUTTING M/C:


This m/c uses acetylene and oxygen in definite proportion to get neutral
flame which work with 32000C temperature.

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

Y-RAYS: It is produced through isotopes of radioactive metals like


Uranium, Cobalt, and Iridium. Half life of Iridium is 74.5 days with 1970 mm penetration whereas half life of Cobalt is 5.3 days with 39-200
mm penetration. Since isotopes keeps on decreasing strength keeps on
decreasing so we have to calculate the distance to be placed.
PROCESS: Cascade containing is placed behind the welded and casted
part. After radiation it is taken to dark room in which 4 cylinders
containing developer, water, fixer and running water. When film gets
dipped in developer a film of particular density get coated. Afterwards it
is washed through water. Fixer fixes film of particular density so that no
further reaction could take place. Sensitivity is checked through
panotrometer. The film is then placed in strong light to detect the fault
and according to code check its compatibility.

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.

HYDRO & AIR TEST


Hydro test is a capacity test where as air test is a leakage or minor fault
test. Helium test could also be performed as it can detect more minor
defects. On the basis of casting of material the limiting pressure is
decided. Test is done with 1.25 to 1.5 times the working pressure which
is under the limiting pressure.

DYNAMIC BALANCING TEST


When the job is in rotation, the bearings sense the vibration. The
magnetic system amplifies it to display the defect or extra mass position.
Marks are over the job at certain angles so that defects accurate
location can be detected. There are different type of balancing such as
single plane balancing, double plan balancing. According to the bore of
impeller there is mandle. Digital reading shows weight, angular position
of defect, and rpm. We use electric grinder to balance the unwanted
mass and further test is done until no defect is detected.

PUMP ASSEMBLY TESTING


Parameters such as NPSH, power, efficiency, mechanical properties
such as vibration, temperature withstanding etc. are plotted b/w quantity
vs. head, power & efficiency to check its compatibility.

PRODUCT DESIGN AND DEVELOPMENT (PDD)


The process goes through two stages:
Pre order stage work
Post order engineering work
First the Marketing dept.Advertise the companys production capabilities and contact the vendors and clients. Catalog of models are
presented to the clients. On basis of the collaborator from France
different models are developed with criteria such as head, NPSHR,
power etc. Such that it fulfils the API 610 standards. Pumps are decided
over following factors:
Horizontal/Vertical
Flow (m3/hr) and head which is determined by diameter of impeller
Power :Brake horse power = (Q x H x p)/(367 x n)
Q flow; H Head; p specific gravity; n efficiency
In BPCL the available models are:
1) OH2: It is overhung; flexibly coupled; horizontal with centreline
mounted type of centrifugal pump.
2) BB1: It is between bearings; 1& 2 stage; axially split type of
centrifugal pump.
3) BB2: It is between bearings; 1& 2 stage; radially split type of
centrifugal pump
4) BB3: It is between bearings; multistage; axially split type of
centrifugal pump
5) VS1: It is vertically suspended; single casing; discharge three
column; diffuser type centrifugal pump.
6) VS2: It is vertically suspended; single casing; discharge three
column; volute type centrifugal pump.
7) VS6: It is vertically suspended; double casing; discharge three
column; diffuser type centrifugal pump.

8) VS7: It is vertically suspended; double casing; discharge three


column; volute type centrifugal pump.

Main parts and models of centrifugal pumps are:


1) Pump casing 2) Bearing housing 3) Pump shaft 4)Internal cover
5)external cover 6) Stuffing box 7) Ball Bearings 8) Roller bearing
9)base plate 10) Electric motor 11) Bearing isolator 12) Vent and
drain pipeline 13) Disc elbow 14) Diffuser box 15) Motor stool 16)
Barrel 17) Case bearing 18) Impeller bearing
Sl Pump
No Model
.
1. SMK Horizontal
singles/double stage
overhung impeller
with water cooled
bearing housings
with top oriented
discharge & vertical
/end oriented
suction. Provision
for inducer
2. KSM Horizontal
K
single/double stage,
shaft supported at
both ends in
bearings with water
cooled housing,
suction and
discharge nozzles
top oriented.
3. LH/B Horizontal sin-gle
LH
stage,Axial split
close to centre line
firm sup-port to
shaft at both ends,
double eyed
impeller with axial
entry and radial
discharge
4. DVDS Horizontal split
casing single/double

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

As above but maximum


suction pressure 52
Kg/cm2

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.

VMB/ Vertical, barrel type, 5 to 100 20 to


VM
multistage pump
500
with/ without Barrel
pumps.

-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

For high pressure and


medium capacity duties
in process industries,
fertilizer, refineries,
power plant, pipeline
services, reinjection in
oil fields, jet blasting in
steel plants and boiler
feed services in thermal
and nuclear plants.
Low pressure and high
discharge application
for handling abrasive,
corrosive viscous and
sugar industries and for
slurry applications.

10

Suitable for booster


22
pumps for main
pipeline, condensate and
cooling water pumps,
V-Wet pit installation
&VB-Low NPSH
application.
Suitable for handling
9
low density petroleum
products and liquefied
gases. Also due to flat
Q-H characteristics
suitable for variable
flow requirements.
Nuclear power plant
5
moderator service and
other critical services
those in Seismic Zones.

RECIPROCATING PUMPS:
There are two types of reciprocating pumps:

1) MUD PUMP (PISTON PUMP)


Available models are: A850-PT, A1100-PT, A1400-PT and A1700-PT
It is a part of drill (Rig). There are many types of assembly involved
such as:
Power end assembly

Fluid end assembly

Crankshaft assembly

Diaphragm assembly

External assembly

internal assembly

linear piston assembly


Jack shaft assembly

Heat exchanger 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

Fluid end assembly


valve assembly

Crankshaft &pinion
lubricator assembly

Built in gear reduction 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.

GAS CYLINDER PLANT


BPC Industrial cylinders range are for various gas applications like
permanent gases such as Oxygen, Air, Argon, Helium, Hydrogen,
Nitrogen, and liquefiable gases such as Carbon-di-oxide and Nitrous
Oxide etc. in conformation with IS 7285 Part-II-2004, Gas cylinder
rule and Chief Controller of Explosives. BPCL also provide BIS test
certificates and filling permissions along with the cylinders.

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 7285 (Part II &


Part I) 2004

IS 15490: 2004

IS 7285 (Part II):


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.

Description of Machines & Size


Equipments

4.

CNC
Hot
Spinning
Machines
Induction Heating Furnace
Bottom Forming Hydraulic
Press
Hardening Furnace

5.

Tempering Furnace

6.
7.

Neck ring Caulking Machine


Drilling Machine

8.

Taper Hole Milling Machine

9.

Taper Reaming Machine

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

Industrial Bharat Heavy Electricals Limited


National
Thermal
Power
Corporation
Steel Authority of India Limited
OIL India Limited
Gun Carriage Factory
Vaious Private Companies
CNG On-Board Cylinders
Bajaj Auto Ltd., Pune
TELCO, Pune
Scooter Indian Limited, Lucknow
J S Auto, Kanpur
CNG Cascades
Indraprastha Gas Limited, New
Delhi
GAIL Gas Limited, Noida
Avantika Gas Limited, Indore
Tripura Natural Gas Limited,
Tripura
Mahanagar Gas Limited, Mumbai
Maharashtra Natural Gas Limited,
Pune
Bhagyanagar
Gas
Limited,
Hyderabad
Central UP Gas Limited, Kanpur
Green
Gas
Limited,
Lucknow/Agra

Various colours are painted to represent respective gas filled.


Sl.No
1.
2.
3.
4.
5.
6.

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

Upon of Govt. Of India initiative of pollution free environment, the


company started the manufacturing of CNG cylinders and CNG
Cascades from 1995 to facilitate use of CNG as an alternative fuel. BPC
is the only public sector company having in-house infrastructure to
manufacture CNG cylinders and cascades both to cater needs of various
city gas distribution projects, automobile industries and retrofitters. it is
worth mentioning that BPC is the first pioneer company who has
indigenously designed, developed and manufacture the very first CNG
cascade thereby substituting import.