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 Maximum
Pumps 2500 KW
Power
Maximum
140 kg/cm2
Pressure
Maximum
12,000 M3/Hr
Capacity
Fluids Dimineralized water, Sea water, Hydocarbons, Neptha,
Handled LPG, Carbonate Solution, Boiler Feed Water, Benefield
solution, Alkaline and Acidic Solution, Ammonia liquor
and slurry
Reciprocating Maximum
Pumps 1700 KW
Power
Maximum
675 kg/cm2
Pressure
Maximum
315 M3/Hr
Capacity
Fluids Drilling Mud, Cementing Slurry, Crude Oil steam,
 Handled Condensate, Heavy Water, Fatty Acids, Ammonia
Carbonate, Liquid Ammonia, Water Injection
Reciprocating Compressors
Maximum
25,000 KW
Power
Maximum
450 kg/cm2
Pressure
Maximum
70,000 NM3/Hr
Capacity
Fluids Air, Nitrogen, Oxygen, Carbon Di-Oxide, Hydrocarbons,
Handled Ammonia, Synthesis Gas, Hydrogen Sulphate, Coal Gas etc.
GAS CYLINDERS
Maximum
400 kg/cm2
Pressure
Maximum
110 Litres.
Capacity
Fluids Oxygen, Nitrogen, Hydrogen, Argon, Air, Helium, Carbon Di-Oxide,
Handled 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 Long Term

Objective To Preventive
Maximise Profits Maintenance
And Minimise Contract - Low
Cost Of The Cost,
Customer Low Downtime

Just In Time Continuous

Spare Parts And Rapid
Management- Technological
Low Downtime Upgradation
 On The Job Training Programme For
Customer Operational & Maintenance
Personnel

BPCL TECHNOLOGY COLLABORATION

PRODUCTS COLLABORATOR
1. Centrifugal Pumps Pomes Guinard, France

2. Reciprocating Pumps Oil Well, USA

3. Reciprocating Compressors Nuovo Pignone, Itly

4. Ammonia & Carbamate Pumps URACA,Germany

5. Cementing Unites B.J. Hughes, USA

6. Slurry Pumps Leument Schneidr. France

7. High Pressure Industrial Gas Cylinders 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 PLANT

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 C
Soaking 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 C
Soaking time 85 min.
Required hardness 1.9 to 2.0 BHM
6. MACHINING OPERATIONS:

i. Turning and facing

ii. Neck ring jamming by cold press
iii. 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 test

2. 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/cm2

CNG ON BOARD 340kg/cm2
CNC 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/cm2

CNG ON BOARD 204kg/cm2
CNC 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 Black
2. 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
PUMP
Pump 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 acting
2. 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 lacs
5. Radial Drill [RF-51]:
Specification:
Drill capacity: 1000 mm
Vertical movement: 1260 mm
Arm length: 3000mm
Value: 4.8 lacs
6. Radial Drill [DR-8]:
Specification:
Drill capacity: 75 mm
Vertical movement: 1050 mm
Arm length: 2700 mm
Value: 2.8 lacs
7. 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 machine
4. Boring machine
5. Turret lathe
In 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. facing
4. Boring
5. counter boring
6. Grooving
7. Taper turning
8. 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 C
2. Salt Bath Furnace: This is used for hardening & Case hardening
Dimension: 400*600 mm
Temperature range: 1400 C
Finished 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 SYSTEM
THE 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
 CONCERNED WITH THE IMPLEMENTATION OF PRODUCTION
SCHEDULES.
PRODUCTION CONTROL GOES ON DURING PRODUCTION AND
CONSISTS ESSENTIALLY OF THE FOLLOWING STEPS ;
INITIATING PRODUCTION
DISPATCHING OF ITEMS (I.E. ESTABLISHING PRIORITIES BETWEEN
ITEMS COMPETING FOR TIME ON THE SAME FACILITIES)
PROGRESSING
REPORTING BACK TO PRODUCTION ENGINEERING.

“PLANNING IS THUS FORWARD THINKING WHILE CONTROL IS A

MECHANISM FOR EXECUTION”.

FUNCTION OF PRODUCTION DEPARTMENT

Product
Design

Quality
Location
Management

Procurement
Schedule Production
Engineering
Department

Reliability
&
Maintenance Layout

Process
Inventory Design
 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.
 Identificati
Identificati on
on and Receipt
location of

Security of
stores Inspection

Function
Of
Stock
Store
control Storage
managemen
t

Issues and Stock

dispatch verification

Surplus
Stock managemen
records t
Stores
accounting

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
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, SWITZERLAND

Advantage: (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 COUNT

1. 100 cm 5 micron
2. 30 cm 1 micron
3. 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 testing

2. Non destructive testing
3. Standard room
4. Assembly testing
5. Chemical lab
6. Mechanical lab
7. Gas control quality control department
8. 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 FACILIT

1. X-ray Radiography:

(a). X-ray machine:

Make: Seifert
Type: PARVORA
Model: ERESCO
Capacity: 300Kw
This is used for steel

(b). X-ray machine:

DYE / LIQUID PENETRATION TEST:
This test is used for detecting surface defects only . The Principle used behind
this 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 Ferrous
2. 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.
 Bought
Out
Items

Semi
Bought Inventory
Type
Bought
Item
Out

Stock
Stiles
 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 effort
Involves 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)

Here the customer starts

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

Then sub-
Then sub- Vend
assembly work is
assembly work is
Fa
pulled forward by
pulled forward by b or
that demand…
that demand… Su
b Fa Vend
b or
Custom Final
ers Assembly
The process continues
The process continues
throughout the entire
Su Fa Vend
throughout the entire b b
production process and or
production process and
supply chain
supply chain
Fa Vend
b or