CHAPTER 1

INTRODUCTION
Bharat Pumps & Compressors Ltd., the public sector corporate enterprises incorporated in
1970with manufacturing facility at Naini, Allahabad, India. It is Certified Integrated
Management Systems Company having ISO 9001:2008, ISO 14001:2004 and OHSAS: 2007
which includes environment, occupational health & safety management systems. The
company manufactures reciprocating pumps, centrifugal pumps, reciprocating compressors
and high pressure seamless gas cylinders.

Figure 1.1: BPCL Logo

1.1 Vision
Mission and Objective of the company is to research, design and develop, manufacture
and supply capital goods in the fluid handling field including provisions of services
connected there with to cater the need of oil exploration and exploitation, refineries and
petro-chemicals, chemicals and fertilizers, power sectors process of downstream industries.
BPC caters to the need of core sectors of the economy such as oil exploration and
exploitation, refineries, petro-chemicals, chemicals, fertilizers. It is indigenously to design
and manufacture heavy duty centrifugal pumps, reciprocating pumps, reciprocating
compressors and high pressure seamless gas cylinders and other hi-tech oil field equipments
such as cementing units, sucker rod pumps etc.

1
 The corporate philosophy also involves approach for Total Quality Management (TQM)
and Total Productive Maintenance (TPM) in order to achieve and sustain a reputation for
Quality at a Competitive Cost, in National & International Markets for our products and
services through collective involvement of all.
BPC is the only Company in Asia to manufacture a wide range of hi-tech products, heavy
duty pumps and compressors and pressure seamless and welded gas cylinders, under one
roof. Such high valued hi-tech products are functioning to the total satisfaction of the
customers with least maintenance cost and optimum energy conservation.
The company has branches/ regional offices at Mumbai, Vadodara, Kolkata, Dibrugarh,
and New Delhi.

1.2 History
BPC was set up in 1970 to cut the country’s dependence on import of hi-tech equipment
like pumps and compressors for use in critical areas like oil and gas exploration, refineries,
chemical and fertilizer plant and nuclear plants. Unfortunately, the company was unable to
make profits. Eventually, it turned sick and was referred to the Board for Industrial and
Financial Restructuring (BIFR). BPC’s losses had accumulated to ₹1,753
million (US$27 million) as on 31 March 2005 and the net worth had turned negative
at ₹1,216 million (US$19 million). The company was referred to the BIFR and was on the
verge of being closed down after 35 years of operations.
The company has seen a dramatic turnaround in its performance from the financial year
2005-06. The company’s profit before tax (PBT) in the financial year 2006-07 was ₹191
million (US$3.0 million), which increased to ₹311 million (US$4.8 million) in 2009-10.
During the same period, its net worth increased from ₹569.6 million (US$8.9 million)
to ₹1,241 million (US$19 million). The turnover went up to ₹2,711 million (US$42 million)
in 2009-10 from ₹1,437 million (US$22 million) in 2006-07. The turnaround of the company
is credited to Mr. Abhay Kumar Jain, who was appointed the MD of the sick company in the
year 2005-06. The special efforts and corporate strategies put in place by Mr. Jain, after
joining on 31.12.2005, yielded the much awaited turnaround of the Company. BPCL
achieved a net profit of ₹1.84crores during Financial Year 2005-06 after accounting for
interest amounting to ₹135 million as against a loss of ₹108.6 million during previous year
2004-05. This remarkable feat of turnaround is of significance since it was achieved without
considering the benefits of financial restructuring. Presently, the company is again running in
loss. Surprisingly, Mr Jain invested nearly ₹100crores in purchase of new machines and had
projected business of ₹1600crores. This target was never achieved and as a result, company
has again incurred loss.
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1.3 BPCL Customers
The sectors wise customers of BPCL are:-
1.3.1 Refineries and petrochemical sector
 Indian Oil Corporation Ltd.
 Hindustan Petroleum Corporation Ltd.
 Bharat Petroleum Corporation Ltd.
 Gas Authority of India Ltd.
 Indian petrochemicals Corporation Ltd.
1.3.2 Oil and Gas Sector
 Oil and Natural Gas Corporation Ltd.
 Oil India Ltd.
1.3.3 Nuclear Power
 Department Of Atomic Energy.
 Bhabha Atomic Research Centre.
 Nuclear Power Corporation Ltd.
1.3.4 Fertilizers and Chemicals
 Tata Chemicals and Fertilizers Ltd.
 Fertilizers Corporation Ltd.
 Hindustan Fertilizer Ltd.
 Indo-Gulf Fertilizer Ltd.
 Indian Farmer Fertilizer and Fertilizer Corporation.

1.4 Departments
 Administrative office
 Finance Department
 Purchase Department
 Sales Department
 Personnel Department
 B.P.C.L data store
 H.R Department
 Officers cabin
 Plant Office
 Conference room
 R.P Department

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  C.P Department
 R.C Department
 T.S.X for R.P, C.P & R.
 P.E.X main office for R.P, C.P & R.0 (dispatching also)
 Officers cabin
 Gas Cylinder Plant
 Pumps and Compressors Division
 Training Department
 Construction Department
 Research & Development Department
 Documentation
 Quality Control Department
 Workshop Services Department
 Others such as fire station, union, etc.

Figure1.2: Pumps and compressor division

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1.5 BPCL Technology Collaboration
Table 1.1: BPCL product’s collaboration

Products Collaborator

Centrifugal pumps Pompes Guinard, France

Reciprocating pumps Oil well, USA
Reciprocating pumps Nuovo Pignone, Italy
Ammonia pumps URACA, Germany
Cementing units B.J. Hughes, USA
Slurry pumps Jeument Schneidr, France
High pressure industrial gas cylinders Showa Koatsu, Japan

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 CHAPTER 2
GAS CYLINDER PLANT
The gas cylinder plant at BPCL is an amazing one, where heavy machinery is manufacture
both high pressure and low pressure cylinders. These are used for both domestic as well as
industrial purposes. There are three departments within the gas cylinder plant namely:

 CNC machining
 Heat Treatment
 Finishing

2.1 Process involved in manufacturing seamless gas cylinder

Seamless gas cylinder is manufactured at BPCL by closing the pipe end on CNC hot roller
spinning machine.
The set procedure for manufacturing seamless gas cylinder involves the following
sequential operations:

 Cutting of pipe
 Doming
 Bottom forming
 Necking
 Heat treatment
 Machining operations
 Cleaning
 Testing
 Shot Blasting
 Colour coding

2.2 Cutting of pipe

The raw material for manufacturing of seamless gas cylinder A pipe that is available in
multiple lengths. It is imported from other countries such as Japan. The pipes are cut
according to size of the cylinder.
Machine Used : Belt cutting saw (CNC)
Manufacturer : INDTOOLS
Dimension of cylinder : 1535mm (length); 232mm (diameter)

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 Lubricant used : Servo cooling oil

2.3 Doming
After cutting the pipe of suitable length, it is heated in an induction furnace to a
temperature up to 1100 deg C. It is then automatically loaded on the CNC hot spinning
machine where the heated end is rolled into a dome shape.
Machine Name : CNC hot spinning machine (Heavy duty EN-500)
Capacity : 40 cylinders per hour
Work piece length : 2220 mm (MAX)
Work piece diameter : 100-275mm
Suitable for : necking of bottles and tubes

2.4 Bottom Forming

After doming the domed cylinder end is again heated and loaded in an HMT press. The
press is used to form bottom by pressing it with dies. It is hydraulically operated and pressing
is done according to requirement.
Machine Used : HMT-press (CNC)

2.5 Necking
It is the operation of making neck at the other end of the cylinder. This is done on another
hot spinning CNC machine with roller. Some part of the end is cut after necking completion
because at end material becomes oxidized. Each necking is performed in 9 passes. The angle
of roller feed increases upto the first 3 passes and then it decreases to zero. A pyrometer is
also installed with a flame detector.
Machine Name : CNC hot spinning machine
Manufacturer : MX, USA
Capacity : 35 cylinders per hour
Work piece length : 2500 mm (MAX)
Work piece diameter : 232-406 mm
Wall thickness : 3-15 mm
Lubricant used : MOBIL SHC-634

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 Bolt : M 12 - 1.75 X 70 replaced after every 500 hours of operation.
The pressures set for necking 215 51 follows:
Chuck set pressure : 41 bar
Roller set pressure : 41 bar
Slide up/down : 76 bar
End slide set pressure : 69 bar

2.6 Heat Treatment

Before going to the machining line, the cylinder is heat treated in order to ensure that the
cylinder retains its hardness which might be lost during the above operations. The heat
treatment procedure is as follows:

 Hardening furnace
 Quench tank
 Tempering furnace

The cylinder is heated in a furnace up to 850 degree Celsius for 30 minutes. The furnace is
oil fired which uses a mixture of air and diesel for combustion. The mixture is sprayed with
the help of nozzles. The cylinder becomes "red-hot". It is then quenched in a solution of
polyamide water for two minutes. It is then passed on to the tempering furnace where it/I
heated upto a temperature of 550 degrees Celsius for 45 minutes and allowed to cool slowly
in air to toughen the material and to relieve it of its internal stresses and micro cracks.

2.7 Machining operation & cleaning

After heat treatment several series of operations are performed to complete the open end
of the cylinder, to produce threads and to clean the insides of the cylinder. The operations
performed in sequence are:

 Facing and chamfering

 Caulking
 Drilling (locator is required to hold the job)
 Milling the hole (with locator)
 Reaming (with locator)
 Hob threading (with locator)

Cleaning process inside of the cylinder is done using steam from boiler and wire brushing.

8
2.8 Testing
The tests performed are as follows:

2.8.1 Hydro-stretch testing:

This test is performed by filling the gas cylinder with pressurized water to allow the
cylinder to expand under water. The cylinder, once stretched ,cannot be stretched any further.
Water is then drained out and the cylinder is dried.
2.8.2 Air leakage testing
This test is done to check for air leakages through cracks. The cylinder is filled with
pressurized air and immersed in water. If bubbles emerge, it means the cylinder is defective.
If the cracks are small, the cylinder is coated with some lining and passed for further
operations otherwise it is discarded. The air is discharged after the end of the test.
(The test pressures are different for different cylinders in both tests.)

2.9 Shot blasting

This is performed to clean the outer surface of the cylinder. A hot stream of air along with
some abrasives is allowed to pass over the outer surface of the cylinder, thus cleaning its
outer surface. Sometimes vacuum cleaning is also done after shot blasting.

2.10 Colour coding & painting

After all the above operations have been performed, the final step is the colour coding of
the cylinders. Painting is done manually with the help of spraying machine in which or and
paint are passed through separate inlets. The colour coding is as follows:
Black : Oxygen
Blue : Argon
Red : Hydrogen
Black and white : Carbon dioxide
White and red : CNG
After colour coding stamping is done, i.e., the working pressure, testing pressure, batch
no, gas filled etc. are written over the cylinder. At the end these cylinders are tested by ISI
members to confirm the quality and safety measures.
(The production of welded gas cylinder, LPG gas cylinder and porous mass cylinder has
been stopped by BPCL due to various economic reasons).

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 CHAPTER 3
PRODUCT DESIGN DEPARTMENT
The product design department (PDD) at BPCL deals with the design of:

 Centrifugal pumps
 Reciprocating pumps
 Reciprocating compressors

3.1 Pumps
A pump is a device that expends energy to raise, transport, or compress liquids. All
pumps operate on the above fundamental principle. The following are a few main domains
that use pumps extensively:

 Water supply : To supply water to inhabited areas.

 Drainage : To control the level of water in a protected area.
 Sewage : To collect and treat sewage.
 Irrigation : To make dry lands agriculturally productive.
 Chemical industry : To transport fluids to and from various sites in the chemical plant
 Petroleum industry: Used in every phase of petroleum production, transportation, and
refinery.
 Pharmaceutical and medical field: To transfer of chemicals in drug manufacture;
pump fluids in and out of the body.
 Steel mills: To transport cooling water.
 Construction: Bypass pumping, well-point dewatering, remediation, and genera i site
pumping applications.
 Mining: Heavy-duty construction, wash water, dust control fines and tailings
pumping, site dewatering, groundwater control, and water runoff.
 Pumps can be classified on various bases. Pumps based on their principle of operation
are primarily classified into:
 Positive displacement pumps, which lift a given volume for each cycle of operation,
can be divided into two main classes, reciprocating and rotary. Reciprocating pumps include
piston, plunger, and diaphragm types. The rotary pumps include gear, lobe, screw, vane,
regenerative (peripheral), and progressive cavity pumps.
 Rotor-dynamic pumps, which raise the pressure of the liquid by first imparting
velocity energy to it and then converting this to pressure energy. These are also called
centrifugal pumps. Centrifugal pumps include radial, axi.al, and mixed flow units.
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  Others, which include electromagnetic pumps, jet pumps, gas lift pumps, and
hydraulic ram pumps.
3.1.1 Reciprocating pumps
Reciprocating pumps are further classified as plunger pumps, mud pumps and diaphragm
pumps.
3.1.1.1 Plunger and mud pumps
Plunger pumps comprise of a cylinder with a reciprocating plunger in it. The head of the
cylinder houses the suction and the discharge valves. In the suction stroke, as the plunger
retracts, the suction valve opens causing suction of the liquid within the cylinder. In the
forward stroke, the plunger then pushes the liquid out into the discharge header. The pressure
built in the cylinder is marginally over the pressure in the discharge. The gland packings help
to contain the pressurized fluid within the cylinder. The plungers are operated using the
slider-crank mechanism. Usually, two or three cylinders are placed alongside and their
plungers reciprocate from the same crankshaft. These are called as duplex or triplex plunger
pumps. The mud pumps differ from the plunger pumps in only 1 aspect, i.e., the have a
instead of a plunger in the cylinder. Another variation of plunger pump is the injection pump,
which injects air into the bore in order to facilitate extraction of fluid underground. The main
parts of such pumps include:

 Main casing
 Piston/ Plunger
 Crankshaft
 Connecting rod(s)
 Crosshead(s)
 Gudgeoned pin
 Stuffing box
 Tension rod
 Blind pack
 Fluidic
 Suction and discharge valves
 Suction manifold
 Valve sheet
 Suction damper
 Pressure gauge
 Safety valve

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  Bearing housing

The plunger pumps are used mainly in fertilizer industries where as, the mud pumps are
mainly used in ONGC for exploration and exploitation of oil and natural gas.
The plunger pumps manufactured are: 83-25, 83-20, 83-20R, 63-10, 63-10R, 43-7 and 45.
The mud pumps manufactured are: 1700PT, 1400PT, 110OPT, 1000PT, 85OPT, 700PT
and 600PT.
The following table on the next page shows the range of reciprocating pumps
manufactured at BPCL:
Table 3.1: Range of reciprocating pump

Maximum Power 1268.2 KW

Maximum Pressure 675 kg/cm2

Maximum Capacity 315 m3/hr

Fluids handled Drilled mud, crude oil, slurry, heavy

water, steam condensate

3.1.2 Centrifugal pumps

The centrifugal pumps are by far the most commonly used of the pump types. Among all
the installed pumps in a typical petroleum plant, almost 80-90% are centrifugal pumps.
Centrifugal pumps are widely used because of their design simplicity, high efficiency, wide
range of capacity, head, smooth flow rate, and ease of operation and maintenance.
The centrifugal pump has a simple construction, essentially comprising a volute and an
impeller. The impeller is mounted on a shaft, which is supported by bearings assembled in a
bearing housing. A drive coupling is mounted on the free end of the shaft.
The prime mover, which is usually an electrical motor, steam turbine, or an IC engine,
transmits the torque through the coupling. As the impeller rotates, accelerates, and displaces
the fluid within itself, more fluid is drawn into the impeller to take its place; if the pump is
properly primed. The impeller thus, impacts kinetic or velocity energy to the fluid through
mechanical action. This velocity energy is then converted to pressure energy by the volute.

12
The pressure of the fluid formed in the casing has to be contained and this is achieved by an
appropriate sealing arrangement. The seals are installed in the seal housing. The normal
operating speed of pumps is 1500 rpm (1800 rpm) and 3000 rpm (3600 rpm). However, there
are certain designs of pumps that can operate at speeds in the range of 5000-25 000 rpm.
Centrifugal pumps maybe single or multistage. Multistage centrifugal pumps are
'hydraulically balanced' by manipulating the flow of liquid within stages.
The main parts include:

 Impellers
 Pump casing
 Stuffing box
 Shaft
 Bearing housing Mechanical seals
 Suction and discharge ports

3.1.2.1 BPCL range for centrifugal pumps

The range offered is:
Capacity : Maximum upto 1200m3/hr
Head : Maximum upto 1500m.
Liquid Temperature : -200 deg C to 400 deg C
Speed : Upto 6500rpm
Table 3.2: Details of centrifugal pumps

Pumps Model Construction No. of stages

SMU/SMK/KSMK Horizontal Single& Double
LHF/LH/MPE Horizontal Single
PLC Vertical (Submersible) Single
DVMX Horizontal Upto 14 stages
LC Horizontal Single
VM/VMB Vertical(barrel type) Upto 24 Stages
V/VB Vertical(barrel type) Upto 32 Stages
DVDS Vertical(barrel type) Upto 32 Stages
EVS Horizontal Upto 32 Stages

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3.1.3 Horizontal pumps
3.1.3.1 SMU/SMK/KSMK

 These pumps are heavy duty, single and double stage.

 These are radial split; centrelines mounted and are of horizontal construction.
 The design conforms to API — 7K standard.
 The difference lies in the type of cooling and the support of impeller.
 The discharge is top oriented and the suction maybe top or end oriented. 1- Pull out
features thus making maintenance easy.
Table 3.3: Range of Horizontal pumps

RANGE SMU SMK KSMK

Impeller Support Overhung Overhung Simply Supported
Cooling Air-Cooled Water Cooled Water Cooled
Max Capacity 1000m3/hr 1000m3/hr 1000m3/hr
Max head 200m 350m 550m
Pumping -190 to 400 deg C -190 to 450 deg C -190 to 450 deg C
Temperature
RMP 3600 3600 3600
Application

 Petrochemicals
 Refineries
 Fertilizers
 Thermal power stations

3.1.3.2 DVMX

 Double Volute Multistage horizontal pumps for high pressure and medium capacities
with axial split casing and near centreline support.
 The design conforms to API —7K standard.
 Special design feature includes hydraulic balancing by opposed arrangement of
impellers and simple bearing construction.

Range
Max capacity : 1000 m3/hr

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 Max head : 1400 m
Pumping temperature : 120 to 250 deg C
RPM : upto 3600
Designation
DVMX 3 4 9
3 -Discharge nozzle site in inches
4 -Suction nozzle size in inches
9 -Impeller size in inches
Application

 Process industries
 Fertilizers
 Refineries
 Power plants for boiler feed service
 Pipelines

3.1.4 Vertical pumps

 VM/V are submersible types whereas, VMB/VB are with barrel construction for low
NPSH application.
 Medium duty vertical process pumps.
 Design conforms to API-7K standard.
 Easy maintenance.
Table 3.4: Range of Vertical pumps

RANGE Max VM/VMB V/VB

Capacity 1000 m3/hr 6400 m3/hr

Max head 500m 870m

Pumping temperature -200 to 220 deg C -200 to 220 deg C

15
Designation
These pumps are designated by their optimum capacity and optimum differential head.
VM 8 X 12
8 -Capacity in m3/hr
12 - Differential head in meter.
Application

 Chemical and petrochemical.

 Fertilizers
 Refineries
 Cryogenic service
 Nuclear service.

3.2 Compressor
A compressor is a device used to increase the pressure of a compressible fluid. The inlet
pressure can be any value from a deep vacuum to a high positive pressure. The discharge
pressure can range from sub-atmospheric levels to high values in the tens of thousands of
kilograms per square centimetre. The inlet and outlet pressure are related, depending upon the
type of compressor and its configuration. The fluid can be any compressible fluid; either gas
or vapour and can have a wide molecular range. Applications of compressed gas vary from
consumer products, such as home refrigerators to large petrochemical plant installations.
The compressors manufactured at BPCL, Allahabad are those using mechanical motion of
a piston (reciprocating type) to effect the compression. These types of compressors are
widely used in the process and gas distribution/transport industries. These compressors use
intermittent compression mode and are referred to as 'positive-displacement compressors'.
3.2.1 Reciprocating compressor
The reciprocating compressor is the best known and the most widely used of all
compressors. It consists of a mechanical arrangement in which reciprocating motion is
transferred to a piston which is free to move in a cylinder. The displacing action of the piston
together with the inlet valve(s) allows a quantity of gas to enter the compressor where it is
compressed and then discharged. Action of the discharge valve prevents the gas to flow back
into the compressor during the next cycle intake. The compressor is 'single-acting' if the
compression takes place on one side of the cylinder and 'double-acting' if it takes place on

16
both sides of the piston. The range of compressors manufactured by BPCL is given in the
following table:
Table 3.5: Range of Reciprocating compressor

Maximum Power 2500KW

Maximum Pressure 450 kg/cm2

Maximum Capacity 70000 m3/hr

Fluids handled Air, nitrogen, carbon dioxide,

hydrocarbons, ammonia, etc.

3.2.1.1 Design aspect

The design for pumps and compressors is made by the design department. There are two
separate design departments for pumps and compressors.
It is connected by a hinge at one end and free at other and can be moved up and down. A
scraper chain with buckets is fitted to it, which carry material to next conveyor. The buckets
present on the chain collect the material loosened by the harrow and discharge it on other
side.
It consists of a cylindrical shell with an arrangement for the rotation of the shell. Its shell
is made up of a special steel with a thick refractory lining on the inside walls. The kiln is
supported at three points by rollers and by the collars at both ends. It is divided into two
portions by a ring placed inside. The first portion is quenching section where the red-hot
material is quenched by water. The water is sprayed by the nozzles provided on the inside
walls of the shell. The next section is drying section. Here the quenched material is dried with
the help of the same steam generated during quenching.

17
Both departments have similar construction with the following sections:
Table 3.6: Design aspect of Reciprocating compressor

S.NO. SECTION WORKING

1. Application/ job section Structure of the tenders and prepare the
offer to suit the customer's requirement

2. Execution section After getting the orders, this section

prepares the departmental purchase
indent, bill of material, drawings and
issue to respective section for further
actions

3. Estimation section As per scope of supply, this section

estimates the involved cost (Material and
manufacturing cost)

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 CHAPTER 4
PUMPS & COMPRESSOR PLANT
The pumps and compressors plant (PCP) is the manufacturing section for the pump,
compressor and spare parts. PCP is divided as:

4.1 Pumps & compressors manufacturing

This section mainly handles the assembly, testing, packing and dispatching of centrifugal,
reciprocating pumps and reciprocating compressors.

4.2 Feeder
This section consists of six bays. This is the section where preassembly working is done.
In this section all machining, fabrication and heat treatment operations are carried out.

4.3 Bay 1
Bay is the place between long walls on which the rail is situated and overhead cr.ine is
used to carry the heavy machine components from one place to another. Bay-1 is the heavy
machine shop. The machines available are:
4.3.1 Vertical Borer BV-25

 Manufacturer : H.E.C. Ranchi, India

 Table diameter : 2400mm
 Vertical travel : 1500mm
 Cross travel : 140Ornm
 Safe Load : 10000 kg
 Value : 22lakhs

(The machine has two tool holders arid can be both manually as well as automatically
operated. As the machine has no tail stock operations such as drilling, reaming, etc cannot be
performed on it)
4.3.2 Plano Milling

 Supplier : Batliboi
 Table diameter : 4000mm
 Table traverse : 3700mm
 Maximum load : 10 tons
 Axial travel of spindle : 250mm

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  Height of the machine : 4050mm
 Value : 1642lakhs

4.3.3 Horizontal Boring machine (BFT-125)

 Spindle diameter : 125mm

 Boring diameter : 800mm
 Boring depth : 1120mm
 Diameter of flat plate to spindle depth : 2700m
 Maximum height of job : 1040mm
 Safe load : 300kg
 Vertical traverse : 1040mm
 Longitudinal traverse : 2000mm
 X-traverse : 1600mm
 Value : 8.5lakhs

4.3.4 Cylindrical grinder [BUA – 631]

 Swing : 630mm
 Centre distance : 3000mm
 Value : 6.0lakhs

4.3.5 Radial Drill [RF — 511]

 Drill capacity : 1000mm

 Vertical movement : 1260mm
 Arm length : 3000mm
 Value : 4.8lakhs

4.3.6 Radial Drill [DR -8]

 Drill capacity : 75mm

 Vertical movement : 1050mm
 Arm length : 2700mm
 Value : 2.8lakhs

4.3.7 Centre lathe [LC-100]

 Centre length : 6500mm

 Swing : 1000mm
 Safe load : 10000kg

20
  Value : 8.0lakhs.

4.3.8 Vertical turret lathe

 Table diameter : 1425mm

 Job height : 1600mm
 Vertical travel : 750mm
 Turret travel : 650mm
 Value : 8.0lakhs

4.4 BAY2
This is the light machine shop 0606 041 consists of center lathes, Production lathes, small
size radial drilling machines, boring machines and turret lathes. in this shop mainly small
Size components are prepared such as impeller of centrifugal pump and shaft keys, bushings,
etc. This bay also contains the balancing machine where the impellers of the centrifugal
pumps are balanced dynamically.
4.4.1 Dynamic balancing machine

 Model : HS-10061S (S.No.1212)

 Capacity : 1500 kg ; 1600 diameter
 Speed : 200 -2000 rpm
 Motor : 10 HP (1500 rpm)

4.5 BAY 3
Bay 3 is the fabrication shop where the beds for pumps and compressor are fabricated.

4.6 BAY 4
Bay 4 has two main cutting machines:
4.6.1 Bend saw cutting machine (hydraulically operated)

 Capacity : 340mm (round bar) ; 440mm (flat bar)

 Minimum speed : 140m/min
 Maximum speed : 240m/min
 Material to cut : C-40, C-20, 4140, H-11, etc.

21
4.6.2 Profile gas-cutting machine CNC
This machine uses dissolved LPG and oxygen mixture for cutting. It has a scanner which
scans the profile to be cut and then automatically cuts the prescribed profile. The maximum
thickness that can be cut using this machine is 100 mm. The nozzle diameter has to be
changed for cutting plates of different thickness.
Table 4.1: Different nozzles and their cutting range

NOZZLE DIAMETER PLATE THICKNESS THAT CAN BE

CUT
1/32” 6-12mm
3/64” 12-25mm
1/16” 25-40mm
3/32” 40-63mm
1/8” 63-100mm

Figure 4.1: Pump and Compressor Plant

22
 CHAPTER 5
HEAT TREATMENT SHOP
Heat treatment is done to alter the mechanical properties of the material. The material may
be a part of the compressor, pump or any other machine element. The operations performed
are:

5.1 Case hardening and carburizing

This refers to the diffusion of carbon particles within the work piece. The material has to
be in a finished condition because generally no further machining operations are possible.
Only some grinding allowance is given. The maximum depth of carbon penetration is 3 mm.
Carburizing is possible in steels having carbon percentage less than 0.25%. Selective
carburizing is also done in some cases. Different types include pack carburizing (charcoal),
cyaniding (sodium cyanide) and gas carburizing (methane).

5.2 Tempering
Tempering is done after hardening to relieve the material of micro cracks and to toughen
the material. In this process the material is heated below the lower critical temperature and
allowed to cool slowly in air.

5.3 Normalizing
The normalizing of steel is carried out by heating approximately 100 °C above the upper
critical temperature followed by cooling in air to room temperature. It is done to obtain a
relatively good ductility without reducing the hardness and strength.

5.4 Annealing
It is a process that produces conditions by heating to above the recrystallization
temperature, maintaining a suitable temperature, and then cooling. Annealing is used to
induce ductility, soften material, relieve internal stresses, refine the structure by making it
homogeneous, and improve cold working properties.

5.5 Stress relieving and other hardening operations

Stress relieving is applied to both ferrous and non-ferrous alloys and is intended to remove
internal residual stresses generated by prior manufacturing processes such as machining, cold
rolling and welding. Without it, subsequent processing may give rise to unacceptable
distortion and/or the material can suffer from service problems such as stress corrosion
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cracking. The treatment is not intended to produce significant changes in material structures
or mechanical properties, and is therefore normally restricted to relatively low temperatures.

5.6 Furnaces used

The furnaces used are:
5.6.1 Muffle furnace (Induction type)

 Range : 100-1200 degree Celsius

 Material of coil : Ni-Cr

5.6.2 Electric furnace [17B.03]

 Diameter : 1800mm
 Depth : 2000mm
5.6.3 Mar-tempering furnace
 Range : 0-1000 degree Celsius
5.6.4 Electric furnace [17B.06]
 Range : 0-1000 degree Celsius
 Diameter : 1900mm
 Depth : 3500mm

5.6.5Therelec furnace
5.6.6 Ammonia nitride furnace

5.7 Quenching tank

The quenching media used in decreasing order of soaking time are air, oil and water. The
media and the time depend on the material and the temperature of heat treatment. The
quenching tank is 12750 X 2750 X 4000 mm in size. [178.02]

5.8 Welding shop

Welding is a process of fabrication of two or more metal parts. This is often done by
melting the work pieces and adding a filler material to form a pool of molten material (the
weld pool) that cools to become a strong joint, with pressure sometimes used in conjunction
with heat, or by itself, to produce the weld. Both manual and machine welding are performed
in BPCL.

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 Pressure may also be used in conjunction with heat, or by itself, to produce a weld.
Welding also requires a form of shield to protect the filler metals or melted metals from being
contaminated or oxidised.
The type of welding can be seen in the following table:
Table 5.1: Types of Welding Processes

SMAW Shielded metal arc welding

GMAW Gas metal arc welding
SAW Submerged arc welding
GTAW Gas tungsten arc welding
PAW Plasma arc welding
ESW Electro slag welding
EGS Electro gas welding
RW Resistance welding
Power source : Transformer, generator or rectifier.
Polarity : Negative for holder and positive for work piece.

5.9 Electrodes used

The following is the list of electrodes used for welding at BPCL:

 Mild Steel Electrode

 Low hydrogen and high tensile steel electrode
 Deep penetration electrode
 Hard surface electrode
 Stainless electrode
 Cast iron and non ferrous electrode
 Carbon dioxide welding wire electrode
(The sizes of electrodes used include: c 2.5 mm X 350 mm; c 3.15 mm X 315 mm; c 4.0
mm X 350 mm; c 5.0 mm X 350 mm)

5.10 Welding procedure

 The welding done is not performed in a single go. It is performed in a number of runs.
 The first run known as the 'root run' is performed using TIG with tungsten as the
negative electrode. Argon gas (99.99% pure) is used for shielding purposes (to prevent
oxidation since the welding is done at high temperatures).

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  The sole purpose of the root run is to allow the weld metal to penetrate at the joint.
 The root gap is kept in between 1.5-2.5 mm.
 The next runs are performed manually using SMAW as TIG is a very costly affair.
 Then grinding is done to remove the extra weld material from the joint. The weld
material chosen is the same as that the parent material.

 The sources used include:

 Welding Generator (AC to DC)
 Welding Transformer (AC to AC)
 Welding Rectifier (AC to DC)

(The welding rectifier is preferred as there is less fluctuation, better performance and less
no of defects)

Figure 5.1: Shielded Metal Arc Welding

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 CHAPTER 6
QUALITY CONTROL DEPARTMENT
The quality control department mainly deals with quality assurance and vendor
assessment. It has control on all feeder sections. It checks quality of the raw material and the
product according to the following prescribed standards:

 ISO 9001-2008
 ISO 14001-2004
 OHSAS 18001-2007
 API-7K

6.1 Standard room

This is the section where the calibration of different measuring instruments is done.
Calibrations are required from time to time so as prevent problems during assembly of the
pump or cylinder components. Some of the instruments in the standard room are:
6.1.1 Master height gauge

 Range : 0-50 mm
 Least Count : 2 microns

It is an indirect measuring instrument.

6.1.2 Point inside micrometer

 Range : 200-225 mm
 Least Count : 0.2 microns

6.1.3 Universal unimaster

 Range : 0.228-3 m (outer diameter); 0.250-3 m (inner diameter)

 Least Count : 10 microns

6.1.4 Concentricity tester

 Range : 200 mm
 Centre height : 100 mm

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 It is used to check the concentricity of cylinders and tapers of gears, threads etc.
6.1.5 Floating carriage micrometer

 Least Count : 2 microns

6.1.6 Electronic hardness tester

This is a portable type hardness tester which works on finished surfaces having roughness
more than 0.1 RC. It works on the principle of rebound velocity. It is capable of giving
readings in both Rockwell and Brinell scale.
6.1.7 Surface finish tester
It gives the average of peaks and valleys in all the three mutually perpendicular directions.
6.1.8 Electronic comparator
6.1.9 Alignment telescope

 Accuracy : 0.1 mm/m

It is used to check whether different bores are within the same centreline or not.
6.1.10 Universal measuring machine

 Least Count : 0.5 microns

It is used basically for thread profile related measurements, but several operations can be
performed on it.
6.1.11 Length measuring machine

 Range : 3m
 Least Count : 1 micron

It is used for calibration of setting rod of screw gauge.

6.1.12 Fiberscope
It is used for viewing the inside porosity of a casting; does not give any measurement.
6.1.13 Profile projector

 Linear accuracy : 2 micron

 Angular accuracy : 1 micron

It is used for measuring angles and lengths. It has 10X, 20X and 50X zoom.

6.2 Radiography testing

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 This test is used to find the internal defects within a casting or a welded joint. Both X-rays
and y-rays are used depending upon the job. The defects are then grooved and removed.

6.2.1 X-Rays
X-rays are used when the job thickness is less than 43mm (for steel). The X-ray machine
is rated at 300 kW, 5mA. The kW is set according to the thickness of the job. The machine
emits X-rays in all directions at a net angle of 50 degrees (20 + 30) from the focal spot.
6.2.2 ɣ-Rays
Ɣ-rays are used for steel thickness between 17-70 mm. The source used is Ir-192. The ɣ-
rays come to halt at the closed end of the machine and are spread out in all directions using a
pin.
This testing can be done for multiple jobs at a time. The photographic film in sheet form is
applied at the back end of the job. The workers are required to wear a batch while performing
these tests. The batches are then sent for testing to check the amount of radiation that the
worker has been exposed to. The films are developed in the dark room, where these films are
put between lead intensifying screens and placed in a flexible cassette. These films are then
dipped in a developer for 4-5 minutes. These are then dipped in a fixer solution and then
finally in water. These are then hung to dry. The defects can thus be easily seen. These are
marked with a glass marking pencil. There exact location on the job is found out and the
defects are grooved out. The job is again radio-graphically tested to ensure the quality and
complete removal of defects.

6.3 Chemical lab

Testing facilities are available for:
6.3.1 Metals

 Ferrous
 Non-ferrous

6.3.2 Porous Mass

 Diatomaceous Earth
 Hydrated lime
 Asbestos
 Silica Flour

6.3.3 Rubber
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6.3.4 Water
6.3.5 Paints and solvents
6.3.6 Oil, lubricants and acetone.

6.4 Testing procedure

 Volumetric
 Gravimetric

Considerable points in different tests:

6.4.1 Paint’s Test

 Drying time
 Scratch hardness
 Viscosity

6.4.2 Water’s Test

 pH value
 Total hardness
 Chlorine percentage

6.4.3 Magnetic Particle Test

 This is used to check surface as well as sub-surface defects (up to 4 to 5 mm).

 The material must be ferromagnetic.
 Both wet and dry methods are used.
 In wet method, iron particles suspended in kerosene oil with bath concentration of
1.2 to 2.4 ml in 100 ml is used.
 In dry method, iron particles are directly used.

6.5 Apparatus used

 Electrolytic Analyser
 Spectrophotometer
 pH meter
 Calorimeter
 Centrifuge
 Moisture balance
 Chemical balance

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  Electric balance
 Viscometer
 Flash point detector

6.6 Mechanical lab

The apparatus used include:

 Universal Testing Machine

 Spring Testing Machine
 Impact Testing Machine(both Charpy and Izode)
 Brinell Hardness Tester
 Rockwell Hardness Tester
 Vickers’s Hardness Tester
 Crushing Strength Machine(for porous mass)
 Tensometer(for testing strength of light material)

6.7 Workshop services

The work of this department is to deal with the maintenance of machines and to prevent
breakdown. The machine parts need to be continuously checked and repaired or replaced
using spare parts. The preventive maintenance is performed every Sunday at BPCL. The
department also deals with the installation of new machinery (also including creation of
platform, setting and curing time of cement so as to facilitate proper running of machinery).
The lifetime of each machine is taken to be 15 years. After this, reconditioning of machine
parts is required to ensure proper working efficiency of the machine. Reconditioning involves
changing or repairing of critical machine parts such as lead screw, bearings, housing, threads,
etc.
The work of this department also includes updating of machine components to ensure
advancement of the company in technological forefront. Some new advancement includes:
 Hydraulic couplings
 Hydraulic torque convertors
 Pneumatic systems, etc.

6.7.1 Hydraulic coupling

A fluid coupling consists of three components, plus the hydraulic fluid:

 The housing, also known as the shell (which must have an oil-tight seal around the
drive shafts), contains the fluid and turbines.

31
  Two turbines (fan like components):
 One connected to the input shaft; known as the pump or impellor, primary wheel
input turbine.

6.7.2 Hydraulic torque coupling

A hydraulic torque converter can be broken down into three main components: the
impeller, the turbine, and the stator.
The impeller, or pump, is a ring of metal blades driven by the engine shaft that transfers
kinetic energy by flinging fluid around. Its spinning motion also draws more fluid into the
centre by creating a vacuum. The fluid from the impeller eventually hits the turbine- a set of
three-ring blades connected to the engine shaft. The pressure from the fluid turns the turbine,
which causes the transmission to spin, thus powering the machine.
The fluid then exits the turbine in the opposite direction, away from the engine and pump
spin. This is where the stator comes in: Made from two non-rotating blade sets and located in
stationary housing between rings of turbine blades, the stator is designed to stop the flying
fluid from slowing the engine by hitting the pump.
6.7.3 Pneumatic systems
Pneumatic systems are powered by compressed air or compressed inert gases. The air
usually has moisture removed, and a small quantity of oil is added at the compressor to
prevent corrosion and lubricate mechanical components. Since the operating fluid is a gas,
leakage from a pneumatic cylinder will not drip out and contaminate the surroundings,
making pneumatics more desirable where cleanliness is a requirement.
Any compressed gas other than air is asphyxiation hazard-including nitrogen, which
makes up 78% of air. Compressed oxygen (approx. 21% of air) would not asphyxiate, but is
not used in pneumatically-powered devices because it is a fire hazard, more expensive, and
offers no performance advantage over air.

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Figure 6.1: Quality Control Department

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 CHAPTER 7
CONCLUSION
BPCL has played a very crucial role in the development of India since its establishment in
1970. The products manufactured by BPCL are working as the heart of operations in many
Oil and Nuclear Sectors.
BPCL has shortcomings of public sector for sure. This is why, it has suffered losses in
recent years in spite of having such a wide market and variety of customers from different
parts of India. But now, owing to various adequate recovery and remedial measures taken by
the managerial authorities, the losses have been reduced and converted into considerable
profit. Presently, the company is looking forward to perform well in the near future and to
compete hard with other such firms.

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