INDEX

INDEX

SL No. CONTEXT

1. Introduction About BPCL Introduction Objective Range of products BPCL Main customers Customer satisfaction BPCL Collaboration

2. Gas cylinder Plant Production of seamless cylinder Process involved

3. Pump Compressors Division Introduction of Pump & Compressors Design Aspect Main Part of Centrifugal Pump Selection Criteria & Testing

4. Production Engineering Department

5. Store management Function of store management Relationship between store and other department

6. Standard Room 7. Quality Control Department 8. Inventory

BHARAT PUMP & COMPRESSOR Ltd. NAINI, ALLAHABAD-211010

Bharat Pump & 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 there with. BPC  caters to the need of core sector of the economy 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 pumps, reciprocating compressors and high pressure seamless gas cylinders and other hi-tech   oil field equipments such as cementing units, sucker rod pumps etc.

VISION

To become an Indian MNC in the field of fluid handling, Gas Compression, Gas storage equipment, Services & Project management.

MISSION

To provide quality products and services to core sector industries with special thrust on Oil and Natural gas, Petrochemicals, Refineries, Nuclear and Thermal power plants, Fertilizers and public transport services complying to health and safety requirements.

OBJECTIVES

To increase market share of our products & services. To maximize customer’s satisfaction by providing quality products and services

within stipulated delivery. To increase the business of spares and rendering prompt after sales services

including refurbishment. Achieve expert turnover of 15% by 2009-10.

INTRODUCTION

Till late 60s, the multinational companies dominated the petroleum sector in INDIA Since these industries were operating in the core sector, it was strategically decided by the Govt. of INDIA to nationalize these companies and bring them under the government control this led to formation of Hindustan petroleum corporation for meeting the requirement as well as spare parts for the important equipments installed in these companies the govt. of INDIA decided to establish Bharat pumps and Compressors limited in 1970 under the ministry of heavy Industries and public enterprise .

The company’s registered office is located in Naini Allahabad, and utter Pradesh INDIA It has branch /regional offices at Mumbai, Chennai, VADODARA, KOLKATA, DIBRUGARH, and NEW DELHI.

AREAS OF OPERATION

Bharat pumps and compressors Ltd. Situated in Trans YAMUNA area of Allahabad is basically engaged manufacturing of heavy duty pumps & Compressors for oil exploration and down stream projects such as Refineries Petrochemicals etc. Other sectors served by the company are Fertilizer. Thermal Power. Hydro and Nuclear power, Steels etc.

The companies also manufacturing High Industrial Gas Cylinders for various applications. Upon govt. of India’s initiative for pollution free environment. The company started the manufacturing of CNG cylinder and cascades from 1995 to facilitate use of CNG as an alternative fuel .BPCL is the only public Sector Under taking having in-housing infrastructure to manufacture CNG cylinders and cascades both to cater to the needs of city GAS Authority of India Limited. Automobile OEMs as well as retrofitters.The company has a high credibility for quality of its products and has acquired ISO-9001-2000 Certification.

This has made M/s Bharat pumps and compressors to achieve and sustain a reputation for quality at a Competitive cost in National and International markets.

Range of Products

Centrifugal Pumps

Maximum Power

2500 KW

Maximum Pressure

140 kg/cm2

Maximum Capacity

12,000 M3/Hr

Fluids Handled

Dimineralized water, Sea water, Hydocarbons, Neptha, LPG, Carbonate Solution, Boiler Feed Water, Benefield solution, Alkaline and Acidic Solution, Ammonia liquor and slurry

Reciprocating Pumps

Maximum Power

1700 KW

Maximum Pressure

675 kg/cm2

Maximum Capacity

315 M3/Hr

Fluids Handled

Drilling Mud, Cementing Slurry, Crude Oil steam, Condensate, Heavy Water, Fatty Acids, Ammonia Carbonate, Liquid Ammonia, Water Injection

Reciprocating Compressors

Maximum Power

25,000 KW

Maximum Pressure

450 kg/cm2

Maximum Capacity

70,000 NM3/Hr

Fluids Handled

Air, Nitrogen, Oxygen, Carbon Di-Oxide, Hydrocarbons, Ammonia, Synthesis Gas, Hydrogen Sulphate, Coal Gas etc.

GAS CYLINDERS

Maximum Pressure

400 kg/cm2

Maximum Capacity

110 Litres.

Fluids Handled Oxygen, Nitrogen, Hydrogen, Argon, Air, Helium, Carbon Di-

Oxide, Nitrous Oxide, Acetylene, Ammonia, Chlorine, Freon, LPG, Compressed Natural Gas (CNG)

CUSTOMER OF BPCL

CLIENTS

  Oil & Natural Gas Commission. Indian Oil Corporation.   Hindustan Petroleum Corporation. Fertilizer Corporation of India Ltd. Indian Farmers Fertilizer Corporation. Gas Authority of India Ltd. Indian Petro-Chemicals Ltd. Madras Refineries Ltd. Oil India Ltd. Bharat Petroleum Corporation.

Engineers India Ltd. National Fertilizer Corporation. Indo Gulf Fertilizers Corporation. Indraprastha Gas Limited. Bongaigaon Refineries & Petro-

Chemicals Ltd. Cochin Refineries Ltd. Tamil Nadu Petro-Chemicals Ltd.

CUSTOMER SATISFACTION

In Time Delivery,Installation Commissioning of Products

Common Objective To Maximise Profits And Minimise Cost Of The Customer

Just In Time Spare Parts Management- Low Downtime

Long Term Preventive Maintenance Contract - Low Cost, Low Downtime

Continuous And RapidTechnologicalUpgradation

On The Job Training Programme For Customer Operational & Maintenance Personnel

BPCL TECHNOLOGY COLLABORATION

PRODUCTS COLLABORATOR1. Centrifugal Pumps

2. Reciprocating Pumps

3. Reciprocating Compressors

4. Ammonia & Carbamate Pumps

Pomes Guinard, France Oil Well, USA

Nuovo Pignone, Itly

URACA,Germany

5. Cementing Unites

6. Slurry Pumps

7. High Pressure Industrial Gas Cylinders

B.J. Hughes, USA

Leument Schneidr. France

Showa Koatsu, Japan

MANUFACTURING CAPABILITIES

BPCL Manufacturing Highlights are: Modern and sophisticated machine facilities having at least CNC Machine,

Assembly, Testing, Heat treatment and Fabrication workshops. In- house facilities of non-destructive testing- Ultrasonic, Chemical analysis,

Digital balancing machine, Most modern boring, and Horing machines. CNC Machine for manufacturing of high pressure industrial gas and CNC

Cylinders. Strong testing facilities for reciprocating compressors. Sophisticated standard room and modern tool room.

GAS CYLINDER PLANTGAS CYLINDER PLANT

ds ds

GAS CYLINDER PLANT

The gas cylinder plant at BPCL one of the most unique plant in country where both high pressure and low pressure cylinder are manufactured. These are used for both domestic as well as industrial purposes.

Cylinders manufactured in gas cylinder plant are :-

1. Seamless gas cylinder .2. Welded gas cylinder .3. Liquefied petroleum gas cylinder .4. Porous mass plant .

1. SEAMLESS GAS CYLINDER

PROCESSES INVOLVED IN MANUFACTURING OF SEAMLESS GAS CYLINDER

Seamless cylinders are made by two methods

1. Closing the pipe end on CNC hot roller spinning machine .2. Piercing billet to form shell and close the end on hot spinning machine .

This process is not used to produce cylinder due to high manufacturing and inspection cost .

Using pipe:

1. Cutting of pipe .2. Dooming . 3. Bottom forming .4. Necking .

5. Heat treatment of cylinder.6. Machining operation.7. Cleaning before testing.8. Testing.9. Short blasting and stamping.10. Color coding.

1. CUTTING OF PIPE :

The raw material for manufacturing of CNC cylinder is pipe that is available in multiple length. These pipes are imported from different countries like JAPAN , FRANCE , ARGENTINA and CHINA is emerging market. Now days the pipes are imported from ARGENTINA. The different heat number according to which we select the cutting blade material used on bend saw machine and perform other operation on pipe. The pipes are cut into part according to size of cylinder.

2. DOMING :

After the cutting of the pipe of suitable length. It is loaded on the hot spinning CNC machine end part of pipe is heated in induction furnace at same time it is rolled and dome is formed.

3. BOTTOM FORMING :

After the doming of cylinder end, it is loaded on the HMT-PRESS machine . HMT-PRESS is used to make bottom by pressing it with dies. It is done according to requirement some footing is also provided.

4. NECKING :

It is the operation of making neck at the cylinder. This operation is done on the hot spinning CNC machine with roller. Some part of neck is cut after necking completion

5. HEAT TREATMENT OF CYLINDER:

The stress are developed during doming, bottom forming and necking. To remove these stresses we perform heat treatment operation on cylinders.Two heat treatment processes which are performed are:

i. HARDENING :

It is the in which steal is heated above its critical temperature. It is held at this temperature for a considerable time and then allowed to cool quenching in quenching oil.For cylinder :Temperature 860+10 CSoaking time 48 min.Quenching media Oil quench (viscosity 60.)Required hardness 1.4 to 1.6 BHM

ii. TEMPERING :

Steel (EN15) after hardening becomes brittle. Develops non visible micro cracks and in strained due to residual stresses. This undesired stresses are removed by tempering. Steel heated below lower critical temperature followed by slow cooling.

For cylinder:Tempering temperature 570 CSoaking time 85 min.Required hardness 1.9 to 2.0 BHM

6. MACHINING OPERATIONS:

i. Turning and facing ii. Neck ring jamming by cold pressiii. Drilling is neck by straight drill iv. Hob milling (14 TPI and 1.8 taper in thread)v. Rimming vi. Hob threading

7. CLINNING ;

1.Write brushing for removal of scale that formed during heat treatment.2. steam cleaning.

8. TESTING :

1. Hydro stress test2. pneumatic or air leaking test.

1. Hydro stress test :

After cleaning the cylinder it is loaded for hydro test to check there capacity. Cylinder filled with water and put in the jacket which is already filled with water. Jacket is connect with berate when cylinder is put in it the extra water filled in berate. After closing the jacket hydraulic press fills the water in it. Presser in side the cylinder normally it is

About 1.5 times of the working pressure. In case of CNC cylinder it is about 425kg/cm2.

H.S.T :

HPI CYLINDER 250kg/cm2CNG ON BOARD 340kg/cm2CNC CYLINDER 425kg/cm2

2. AIR LEAKAGE TEST :

It is performed at working pressure. In air leakage test first fill air in cylinder and then check in water to leakage. In case of CNG cylinder those are manufactured at BPCL is 205 kg/cm2.

HPI CYLINDER 150kg/cm2CNG ON BOARD 204kg/cm2CNC CYLINDER 255kg/cm2

9. SHORT BLASTING:

For painting and stamping on the outer surface we need finished surface. This can be achieved by mixture of short and small abrasive particle. These are blast on cylinder by short blasting machine.

10. COLOR CODING:

After finishing the surface vacuum cleaning is done. Color coding is done to recognized the cylinder. Which gas is filled in it without testing.Here is some color codes which are used at BPCL are-

GAS CYLINDER COLOR

1. Oxygen Black2. Carbon dioxide Black (neck) + white (body)3. Air French blue 4. Organ Peacock blue 5. Nitrogen French gray (body) + black band (neck)6. Hydrogen single red

After color coding stamping is done that is done that is to write working pressure, testing pressure, batch no. and gas filled etc. At end these cylinder are tested by ISI member. They confirm their quality and safety measures.

PUMPS AND COMPRESSOR DIVISION (PCD)

Pump and compressors are two major products produced by BPCL among public sector enterprises in India. BPCL produces pumps & compressors as per customer’s requirement. BPCL produces almost every type of pumps & reciprocating compressors. The PCD consists of –

1. Design department (PDE & CDE)2. Manufacturing department (PCP)

THEORETICAL ASPECTS

PUMPPump is a mechanical device used to increase the pressure energy of the fluid. In the most of cases pumps are used for raising fluids from a lover level to higher lever.

COMPRESSOR

These are the mechanical devises which are used to handle the gases from low pressure with required discharge.

The main difference between pump and compressor is that pumps are used for mainly non-compressible fluid and compressors are used for compresible fluid.

CLASSIFICATION OF PUMPS –

Pumps are mainly classified on the following basis:

On the basic principle of working According to this pumps are two types:

1. Homodynamic type (eg. Centrifugal pump)2. Positive displacement type (eg. Reciprocating pump)

On the basis of cylinder used On this basis pumps are two types:

1. Single acting2. Double acting

CENTRIFUGAL PUMPS

The pumps those works on the centrifugal action of working fluid is known as centrifugal pumps. These are heavy duty process centrifugal pumps for continuous service confirming to word standard i.e. AAPI-60 and ISO.

CENTIFUGAL PUMPS ARE CLASSIFIED AS:

1. Horizontal pumps :Eg.- SMU, SMK, KSMK, DVMX, DVDS

2. Vertical pumps :Eg.- VM, VMB, VB

HORIZONTAL PUMPS:

SMU: These pumps are cantilever type (unbalanced) used for low head & low capacity. Its suction & discharge nozzle are always In horizontal & vertical position respectively. Its bearing housing is air cooled.

SMK: These are cantilever pumps i.e. one end is supported to bearing & other is free to rotate. These are used for heavy duty .

RECIPROCATING PUMPS:

These are positive displacement pumps. These are classified as:

1. PLUNGER PUMPS: These are for making positive displacement of the working fluid. These are use where low discharge and high pressure head is required. Plungers have less cross section area and more length.

2. PISTON PUMPS: These piston are used for making positive displacement of the working fluid. These are used where high discharge and low pressure head.

COMPRESSORS

DOUBLE ACTING HORIZONTALLY BALANCED:

Basic principal: compressor is a set up used for the enhancement in the pressure of fluid (compressible). We are able to increase the pressure of the system upto infinite but some constraints are there which are:

1. Metallurgical aspects.

2. Volume of machine.3. Temperature effect.

DISIGNING ASPECTS

We have to consider following constraints while designing a compressor.

1. No. of stages.2. Cooling system.

(a) Gas chamber.(b) For machine lubrication (bearing)

3. Safety system.

PUMP & COMPRESSOR MANUFACTURING

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

FEEDER: This section consists of five Bays.

BAY-1

This bay is the place between two long walls on which monorail is situated and overhead crane is running. The machines available in the BAY-1 are:

1. VERTICAL BORER (BV-25): Specifications: Manufacturer: H.E.C. RANCHI (India) Table diameter: 2400 mm Vertical travel: 1500 mm Cross travel: 1400 mm Safe load: 10000 kg

Value : 22.0 lacs

2. Plano Milling: Specifications: Supplier: Batliboi Table diameter: 4000 mm Table traverse: 3700 mm Maximum load: 10 tone

Axial travel of spindle: 250 mm Height of machine: 4050 mm Value : 1642 lace 3. Horizontal Boring Machine[BFT-125]:

Specifications: Spindle diameter: 125 mm Maximum Boring diameter: 800 mm Boring depth: 1120 mm Diameter from flat plate to spindle rest: 2700 mm Maximum height of job: 1040 mm

Sage load: 300 kg Vertical transverse: 1040 mm Longitudinal transverse: 2000 mm X transverse: 1600 mm Value: 8.5 lace

4. Cylindrical Grinder: [BUA-63]: Specification: Swing: 630 mm Center distance: 3000 mm Value: 6.0 lacs5. Radial Drill [RF-51]: Specification: Drill capacity: 1000 mm Vertical movement: 1260 mm Arm length: 3000mm Value: 4.8 lacs6. Radial Drill [DR-8]: Specification: Drill capacity: 75 mm Vertical movement: 1050 mm Arm length: 2700 mm Value: 2.8 lacs7. Center Length [LC-100]: Specification: Center length: 6500 mm Swing: 1000 mm Safe load: 10,000 kg Value: 8.0 lacs

8. Vertical Turret lathe [46]: Specification: Table diameter: 1425 mm Job height: 1600 mm Vertical travel (cross roll): 750 mm Turret travel: 650 mm Value: 8.0 lacs

9. Horizontal Boring Machine: Specification: Table type: Sacem-2 Spindle diameter: 210 mm Boring bar diameter: 160 mm Spindle/Ram travel: 1100 mm Ram size: 450*450 mm2 Rotary table diameter: 2000*25000 mm2 Vertical travel: 2500 mm Column travel: 7500 mm Rpm: 2.5-800 Feed: 3-2500 mm Motor: 60 KW

Bay-2, Bay-3, Bay-4 and Bay-5 are light machine shop which mainly contains:1. Central lathe 2. Production lathe 3. Small size radial drilling machine4. Boring machine5. Turret latheIn this shop mainly small size components are made like Impeller of centrifugal pumps and shaft keys, bush cutting of connecting rod.

LATHE OPERATION

1. Plane turning 2. Step turning 3. facing4. Boring 5. counter boring6. Grooving 7. Taper turning8. Reaming 9. Knurling 10. Parting

Etc.

HEAT TREATMENT SHOP

Heat treatment is done for getting desired mechanical property in the material. There are fooling heart treatment operation-

1. Hardening 2. Tempering 3. Normal ling (for forging & cold working)4. Annealing 5. Surface hardening 6. Stress Relieving

FURNACE USED

1. Muffle Furnace: Double chamber chrome 40, 410 Material of coil: Ni-Cr Range: 0-1200 C2. Salt Bath Furnace: This is used for hardening & Case hardening Dimension: 400*600 mm Temperature range: 1400 CFinished products from this furnace are gear design etc. The component heats treated by this furnace are free from oxidation.

3. Mal Temperature Furnace: Temperature range: 0-1000 C

4. Ammonia Nitride Furnace: Temperature range: 0-500 C Dimension: 1000*4000 mm 5. Small Pit Furnace: Dimension: 1500*2000 mm

6. Bit Pit Furnace: Dimension: 1500*3500 mm Temperature Range: 0-1000 C

Main Part Of Furnace:

Chamber (body) Fire bricks Coil Thermocouple

The Control Panel Contains:

Pyrometer Line control Voltmeter Ammeter On/Off switch Recorder (to plot time and temperature graph)

Production Engineering Department

ACCORDING TO RAY WILD, “ PRODUCTION PLANNING (PRODUCTION ENGINEERING) IS THE DETERMINATION, ACQUISITION AND ARRAGEMENT OF ALL FACILITIES NECESSARY FOR FUTURE PRODUCTION OF ITEMS”..IN OTHER WORDS PRODUCTION ENGINEERING IS ESSENTIALLY A PRE – PRODUCTION ACTIVITY, ASSOCIATED WITH THE DESIGN OF THE PRODUCTION SYSTEMTHE PRODUCTION SYSTEM IS CONSIDERED TO INCORPORATE AN ORGANISATIONAL ELEMENT IN ADDITION TO PHYSICAL FACILITIES.PRODUCTION ENGINEERING IS CONCERNED WITH ORGANISING THE PRODUCTION OF AN ITEM PRIOR TO THE COMMENCEMENT OF PRODUCTION

PRODUCTION CONTROL IS THE COROLLARY TO SHORT TERM PRODUCTION ENGINEERING OR SCHEDULING, AND IS QUITE SIMPLY

QualityManagement

Schedule

Reliability&

Maintenance

InventoryProcessDesign

Layout

Procurement

Location

ProductDesign

ProductionEngineeringDepartment

CONCERNED WITH THE IMPLEMENTATION OF PRODUCTION SCHEDULES.PRODUCTION CONTROL GOES ON DURING PRODUCTION AND CONSISTS ESSENTIALLY OF THE FOLLOWING STEPS ;INITIATING PRODUCTIONDISPATCHING OF ITEMS (I.E. ESTABLISHING PRIORITIES BETWEEN ITEMS COMPETING FOR TIME ON THE SAME FACILITIES)PROGRESSINGREPORTING BACK TO PRODUCTION ENGINEERING.

“PLANNING IS THUS FORWARD THINKING WHILE CONTROL IS A MECHANISM FOR EXECUTION”.

FUNCTION OF PRODUCTION DEPARTMENT

Store Management

Storekeeping is a service function which deals with the physical storage of goods under the custodianship of a person called storekeeper or store – controller. Goods stored may be either, “Stores” or “Stocks”. Unworked material or raw materials are usually referred to as “Stores” and the place where they are kept is known as “store-room”. Finished products ready for shipment are usually called “stocks” and are housed in a place called “stock-room”. Storekeeping, therefore, is that aspect of material which is concerned with physical storage of goods.

Location of the store must be based on the activity relationships between store and different departments. A broad concept of store location therefore is –

“Store location is the process of selecting the appropriate site for the store building in the organization and deciding how materials are to be placed inside the store (i.e. deciding the spot in which an item is to be placed) so as to provide efficient and prompt service to the user departments.”

Main function of store are : classification and codification of items to be stored, inwarding materials forwarded by external and internal sources, verification of quantity and quality of incoming materials, storage and preservation, issue and dispatch, maintenance of stock records, stock verification, exercising control on surplus and obsolete stock, stores accounting and administrative control on stock discrepancies, deterioration and accumulation of stocks, and co-ordination and co-operation with interfacing departments.

Store is a service department and needs to interact with almost all departments in the organisation. It needs certain amount of participation, co-operation and information from other departments so to service them efficiently.

RELATIONSHIP BETWEEN STORE AND OTHER DEPARTMENTS

Store, by virtue of its function, must be looked upon as a service department. Efficiency of the organisation depends on efficiency of its store function. And for efficient functioning, the relationships between store and other departments must be very cordial. Although store provides the service, it also needs certain amount

Identification and location of

Security of stores

Stock control

Issues and dispatch

Stock records Stores

accounting

Surplus managemen

t

Stock verification

Storage

Inspection

Receipt

Identification

FunctionOf

Storemanagemen

t

of participation and information from other departments so that store serve their needs efficiently and objectives of the organisation are met appropriately.

The need and duties of other departments in relation to store are discussed below :

1. Purchase department

The links between store and purchase have always been very close. In fact, the store and purchase functions are more or less complementary and that is why in most cases, these two departments are combined / united under the heading of ‘materials management’. Wherever they exist as separate departments, the relationship between them acquire vital importance.

Purchasing is responsible for procurement of all the goods and services required by the organisation. Purchasing relies on store for a wide variety of supportive activities. Store must –

inform purchasing about levels of stocks at any point of time. Up-to date stock situation enables purchasing to procure correct quantities and thereby ensure balanced and economic flow of goods and services.

notify purchasing when stock levels reach danger levels or have been depleted completely.

advise purchase changes in consumption / demand patterns so that stock levels can be re-set wherever required and suppliers informed accordingly.

intimate acceptances and rejections. Store need to issue material receipt reports (or Goods Inward Notes) to enable accounts to clear suppliers’ bills for material accepted and issue rejection notes to suppliers to enable purchasing to obtain replacement of rejected materials.

keep purchase posted of delays in deliveries against purchase orders raised by them.

provide purchase up-to-date and accurate information on performance of goods and services it is providing, especially when purchasing is located far off from the factory.

inform purchase surplus, obsolete, slow moving and scrap items.

Purchase, on the other hand, can help store by –

notifying information on forward purchases so that storage arrangement can be made.

conveying information on likely late receipt of consignments at the store so that appropriate arrangements can be made.

taking up with vendors who do not follow routing instructions or lack paperwork discipline.

2. Production department

Production department is the key user of store services. Store department on its part must –

ensure that all materials needed for production are made available in the right quantities and at the right time.

advise non-availability of requisitioned materials with expected dates of arrival so that production department can re-schedule their production.

propose substitute materials if requisitioned materials not available.

Production department, on their part, must –

provide adequate notice to store about its needs for materials.

provide store the feedback on the performance of materials issued.

not demand or request material to be issued without authorised material requisition.

advise store their production schedule and impending changes in such schedules.

3. Quality Control and Inspection department

Quality control department is responsible for ensuring that materials used and produced by the organisation conform to laid down specifications and inspection is very important part of the process. Store can assist quality control and inspection in the following ways :

i) Store should ensure that all deliveries of goods are held back until they are checked and passed by quality control.

ii) Store must inform quality control no sooner the items are delivered and inwarded.

iii) All items checked and subsequently rejected should held by store until they are returned to supplier (or collected by the supplier). Samples for tests, wherever external inspection is involved, are given to Quality control at the earliest.

iv) Stock labelled rejection should not be allowed to mix with working stock.

Quality control, on their part, must take up the items for inspection without loss of time. And wherever laboratory or field trials are involved, such tests should be organised promptly.

4. Design and Engineering department

Store department must maintain close co-ordination with design and engineering to obtain advance information on timings of new designs or specifications. Feed back data should be provided to design and engineering on items which are likely to become obsolete as a consequence of proposed changes so that they can plan appropriate timings of introduction of new design / standards. Design and engineering must also see if the existing materials can be put to alternative uses.

5. Sales department

The relationship between sales and store is a very significant one. Sales department will expect from store (if store is responsible for governance of warehouse) to provide up-to-date information on finished goods stock. Store is expected to co-ordinate with production and ensure that optimum quantity of finished product is produced, stored and issued as efficiently. Sales staff will expect store to ensure that enough finished stock is available when required.

They will also require store to show extreme ingenuity in prompt issue of spare parts and accessories required for after-sales activity.

Store on their part will like to be provided with forecasts of future demand so as to be able to make plans in terms of storage space and stock levels.

6. Distribution

The relationship between store and distribution assume importance when store has control over finished stocks which have to be distributed to depots and warehouses throughout the organisation’s distribution network.

Distribution will expect store to ensure that adequate stock are available in correct quantities ready to be loaded.

Distribution on their part must provide store with up-to-date information about needs and wants of distribution system. It must give store, as far as possible, adequate notice of loading quantities, destinations, types and marshalling points, to ensure efficient service from the store system.

7. Maintenance department

Maintenance is responsible for ensuring that plant and machinery performs at its designed efficiency. Store department has to ensure that all necessary spare parts, tools and consumables are made available at the right time. Maintenance, on their part, must inform store their requirements well ahead of equipment overhaul schedules.

Also, whenever a new plant or machinery is installed, maintenance should advise the initial quantity of spares to be procured and stocked.

8. Accounts department

The relationship between store and accounts covers several important areas.

Accounts department requires store to confirm the receipt of goods to enable it to pass suppliers’ bills for payment. Store is also required to provide on continuous basis, data on issues of stocks for different work orders, to enable accounts to perform its function of cost allocation to corresponding batches / jobs.

Accounts also relies on store for information on value of stock held, discrepancies and writeoffs, list of obsolete and damaged items etc.

Store, on their part, expects accounts to inform them in advance days of stock verification and provide guidance on stock discrepancies and adjustments.

STANDARD ROOM

This is the suction for the calibration of different measuring instrument used. The apparatus available for calibration & measurement are:

1.’TESA’ UNIVERSAL UNIMASTER: Range: 225-3125 mm for outer diameter : 250-315 mm for the internal diameter

Least count: .001 mm (10 microns) Make: TESA , Switzerland Use: Direct measuring Instrument for large dimensions Outer diameter, inside diameter & linear dimensions.

2. CONCENTRICITY TESTER: Range: Maximum length of job can be set= 200 mm Center height: 100 mm Swivel of measurement head: +/- 90 Make: CARL ZEISS, JENE, GERMANY Use: For inspection of concentricity of cylinders & tapers, toothed Spur gears, bevel gears, warm gears, gear cutter, threaded job etc.

3. ELECTRONIC PORTABLE HARDNESS TESTER:

Make: PROCEQ, SWITZERLANDAdvantage: (1) Its Portability (2) It can check hardness of large components which are not accessible to load on Brinell, Rockwell & Vickers hardness tester.

4. ELECTRIC COMPARATOR:

SL. NO. RANGE ON SCALE LEAST COUNT1. 100 cm 5 micron2. 30 cm 1 micron3. 10 cm 0.5 micron

Make: TESA, SWITZERLAND Use: To check a large quality of identical items comparing to Established Dimension between electronic probe & platform.

Calibration By: NPL, New Delhi.

5. LENGTH MEASURING DEVICE:

Range : 3000 mm Least count: 1 micron Make: CARL ZEISS, JENA , SWITZERLAND Use: for calibration of standard test piece of outside Diameter ,combined length of inside Micrometer Linear measurement up to 3000 mm. Calibrated by : NPL ,New Delhi

6. OPTICAL FIBEROSCOPE:

Make: CLLASSEN , GERMANY Use: It shows the hindering portion of any component which Is not accessible to view with necked eyes.

7. DIAL CALIBRATION TESTER:

Range: ( 0.001-25 ) mm Accuracy: 1 micron Make: MITUTOYO ,JAPAN Use: calibration of dial test indicators (plunger & lever type ) Calibrated by: NPL ,New Delhi

8. UNIVERSAL MEASURING MACHINE: (AB-D optic electronic measuring device)

Range of Measurement: 400 mm - X-axis (longitudinal axis ) 100 mm - Y-axis (transverse axis ) 140 mm - Z-axis (vertical axis )

Least count of the optical scale: 0.5 micron Make: SIP , SWITZERLAND Use: Linear measurement within 0.5 micron Accuracy in 3D ,angular measurement with 10” (seconds) accuracy, thread plug gauges, Thread ring gauges, small holes in Magnified view. Calibrated by: NPL, New Delhi.

9. HELIUM LEAK DETECTOR:

Model: 938-41 Varian, ITALY Accuracy: 2X 10-10 std cc / sec Application: It can check leak rate of the order of

2X10 (-10) std cc/sec By Sniffer & vacuum techniques of the welded, gasketed & heat affected zone of pumps & Compressors components. Calibration: calibrate by standard calibrated leak of 2.4 X 10 (-8 ) std Cc/sec before each test. 10. PROFILE PROJECTOR:

Use: It is used for measuring angles, length with 10X, 20X, 50X magnification.

QUALITY CONTROL DEPARTMENT [QCX]

Quality control department control on all feeder section. It checks the quality of raw material and finished product as per standard. The department can be categorized as:

1. Machine shop inspection & ultrasonic testing2. Non destructive testing3. Standard room4. Assembly testing5. Chemical lab 6. Mechanical lab7. Gas control quality control department8. Stores (QC)

NDT [Non destructive testing]:

This section handles the following test-1. Ultrasonic test (UT)2. Magnetic particle test (MPT)3. Radiographic test (RD)4. Day/Liquid penetration test (LPT)5. Helium leakage test

In above mainly four tests are used:

ULTRASONIC TEST –

This is the test for checking inside defect in the material. Sound of frequency more then 20,000 Hz. (called ultrasonic) is used for the test. A particular machine named Ultrasonic

testing machine is used for the purpose with different probes (viz. normal probes, angle probe of angle 30,45,60,75 degree).

RADIOGRAPHIC TEST –

This test is used for checked the internal defect of the material specially welded joints. These tests are done by X-ray or Gamma rays.

TESTING FACILITIES IN RADIOGRAPHIC LAB 1. X-ray Radiography:

(a). X-ray machine: Make: Seifert Type: PARVORAMIC Model: ERESCO 300/5 LRK Capacity: 300Kw, 5mA This is used for steel thickness up to 43 mm. (b). X-ray machine: Make: ANDREX Type: Unidirectional Mode: Cma-16 Capacity: 160KV, 5mA This is used for steel thickness up to 10 mm 2. Gamma Ray Radiography: By IR-192 Source (t(1/2)=75 days)

(a) Tech-QPS Camera (Remote Operated): Make: USA Model: 660/664 Capacity: 100 KV Working Capacity: 60 KV Shielding material: Uranium This is used for steel thickness 19mm to 75mm Along with test place, penetrameters are used for checking the Standards of radiographs .penetrameters have two types: (1) Wire type (2) Hole type

DYE / LIQUID PENETRATION TEST:This test is used for detecting surface defects only . The Principle used behindthis test is bloating action of the Dye.

CHEMICALS USED: Cleaner (Highly Volatile) Penetrate Developer (Highly Volatile)

SEQUANCE OF OPERATIONS: Pre cleaning Application of Dye Removal of Dye Application of Developer Inspection Post Cleaning

Dwell time for application & removal of Dye id 10 min.

CHEMICAL LAB Testing Facilities available for:

1. Metal:(a) Ferrous(b) Non Ferrous2. Porous Mass:(a) Diatomaceous Earth(b) Hydrated Lime(c) Asbestos(d) Silica Flour

Inventory:

Inventories represent aggregate of those items which are either held for sale in the ordinary course of business or are in the process of production for sale (i.e. work-in-process) or are yet to be utilized/ consumed in the production of goods and services

BPCL divide the Inventory in fallowing four types

1. Bought-out-Items are those finished parts, sub-assemblies or assemblies which are purchased from outside suppliers. These include standard parts as well as parts produced by suppliers to buyer’s design. Piece-parts (or work-made-parts) are those parts which are manufactured at the company’s own plant from the basic raw materials. Ex motor, Instruments etc.

2. Bought Items are those basic unfabricated materials which have undergone no conversion whatsoever since their receipt from the suppliers. They include items like steel (angles, channels, tees, flats, tubes, plates, shafts, etc.) copper, lead, tin, cotton, rubber etc. Raw materials, in other words, are those basic materials from which components, parts and products are manufactured by the company.

3. Semi Bought out are those in which casting, foraging done from out side of BPCL. In general this type pf material is come in inventory when any customer gives some specific type of order and some parts are completed by BCPL’s helping companies.

4. Stock Stiles are those items which are kept in bulk. Like Screw ,nut ,pipes ,any office accessories (pen, copy ,paper wet etc.) etc.

BoughtOut

Items

SemiBought

Out

StockStiles

Bought Item

InventoryType

Inventory Analysis used by BPCL

G-NG-LF analysis (or GOLF analysis) like S-D-E analysis based on the nature of the suppliers which determine quality, lead time, terms of payment, continuity or otherwise of supply and administrative work involved. The analysis classifies the items into four groups namely G-NG-L and F.

“G” group covers items procured from “Government” suppliers such as the STC, the MMTC and the public sector undertakings. Transactions with this category of suppliers involve long lead time and payments in advance or against delivery.

“NG” (O in GOLF analysis) group comprises of items procured from “Non-Government” (or Ordinary) suppliers. Transactions with this category of suppliers involve moderate delivery time and availability of credit, usually in the range of 30 to 60 days.

“L” group contains items bought from “Local suppliers”. The items bought from local suppliers are those which are cash purchased or purchased on blanket orders.

“F” group contains those items which purchased from “Foreign” suppliers. The transactions with such suppliers:

Involve a lot of administrative and procedural work.

Necessitate search of foreign suppliers.\

Require opening of letter of credit.

Require making of arrangement for shipping and port clearance

Lean Production Used by BPCL

An integrated set of activities designed to achieve high-volume production using minimal inventories (raw materials, work in process, and finished goods)

Involves the elimination of waste in production effortInvolves the timing of production resources (i.e., parts arrive at the next workstation “just in time”)Lean is based on the logic that nothing will be produced until it is needed.E.g. Machineries like Grinding machines, Lathe CNC machines (cost of final product will be high so it is economically desirable to maintain low inventories of such products as well as of the raw material)

Pull SystemHere the customer starts the process, pulling an inventory item from Final Assembly…

Here the customer starts the process, pulling an inventory item from Final Assembly…

Then sub-assembly work is pulled forward by that demand…

Then sub-assembly work is pulled forward by that demand…

The process continues throughout the entire production process and supply chain

The process continues throughout the entire production process and supply chain

Customers

Sub

Sub

Fab

Fab

Fab

Fab

Vendor

Vendor

Vendor

Vendor

Final Assembly