PRESENTATION ON VOCATIONAL TRAININGATBHARAT PUMPS & COMPRESSORS LTD

By- DILIP KUMAR MECHANICAL ENGINEERING

INTRODUCTION

Bharat Pumps and compressors Ltd. (BPCL) (A Public Sector Undertaking under the control of Ministry of Heavy Industries & Public Enterprises, Govt. of India), was set up in the year 1970 at Naini, Allahabad.

It is as an import substitution unit for manufacture of sophisticated process pumps and compressors for core sector industries. The company is engaged in manufacture and supply of heavy duty pumps & compressors and high pressure seamless and CNG gas cylinders.

The companies registered office is located at Naini Allahabad Uttar Pradesh India. It has branch and regional offices at Mumbai, Chennai, Vadodara Kolkata, Dibrugarh and New Delhi.

PRODUCTS MANUFACTURE AT BPCL1. CENTRIFUGAL PUMPS

2. RECIPROCATING PUMPS3.RECIPROCATING COMPRESSORS4. GAS CYLENDERS HIGH PRESSURE INDUSTRIAL CYLINDERCNG CYLINDERS

BPCL MAIN CUSTOMER

REFINERIES AND PETROCHEMICALS SECTORIndian Oil Corporation limitedHindustan Petroleum corporation LimitedBharat Petroleum Corporation limitedOIL AND GAS SECTOROil and Natural Gas Corporation LimitedGas Authority of India limitedOil India LimitedNUCLEAR POWERDepartment of Atomic EnergyBhabha Atomic Research CentreNuclear power Corporation Limited

GAS CYLINDER PLANT

Cylinder manufactured in gas cylinder plant are:1: seamless gas cylinder2: Welded gas cylinder 3: Liquefied Petroleum gas cylinder4: Porous mass plant1: SEAMLESS GAS CYLINDER PROCESSES INVOLVED 1. Cutting of pipe 2. Doming3. Bottom forming 4 Necking

5.Heat treatment of cylinderHardeningTempering

6.Machining operationTurning and FacingNeck ring is jammed by cod pressDrillingReaming

7: Cleaning 8: Testing Hydro stress test Pneumatic or air leakage test

9: Shot blasting and stamping

10: Color codingColor coding is done to recognize the cylinder which gas is filled in it without testing.Here is some color code which are used at BPCL are

GAS CYLNDER COLOUR1: Oxygen Black 2: carbon dioxide Black (neck) + white (body) 3: Air French blue4: Organ Peacock blue 5: Nitrogen French grey (body) + Black band (neck)

PUMPS & COMPRESSORS DIVISION

The PCD consists of-

1. Design Department 2. Manufacturing Department THEORETICAL ASPECTSPUMPS - Pump is a mechanical device used to increase the pressure energy of the fluid. In the most of the cases pumps are used for raising fluids from a lower level to higher level.

CLASSIFICATION OF PUMPSRotodynamic type (e.g. centrifugal pumps)Positive displacement type (e.g. reciprocating pumps)CENTRIFUGAL PUMPSIMPORTANT PARTS OF CENTRIFUGAL PUMPS

WORKING PRINCIPLE OF CENTRIFUGAL PUMP The centrifugal pump works on the principle of forced vortex flow which means that when a certain mass of liquid is rotated by an external torque, the rise in pressure head of the rotating liquid takes place.

RECIPROCATIONG PUMPSRECIPROCATIONG PUMPS: If the mechanical energy is converted into hydraulic energy (pressure energy) by sucking the liquid into cylinder in which a piston is reciprocating (moving backward and forward), which exerts the thrust on the liquid and increases its hydraulic energy (pressure energy), the pump is known as reciprocating pump. These are positive displacement pumps. These are classified as:PLUNCER PUMPS: These are use where low discharge & high pressure head is required. PISTON PUMPS: These are used where high discharge & low pressure head.

On the basis of cylinders used- Single acting.Double acting.

WORKING OF A RECIPROCATING PUMP

Fig. show a single acting reciprocating pump which consists of a piston which moves forwards and backwards in a close fitting cylinder.

COMPRESSOR

These are the mechanical devices which are used to handle the gases from low pressure with required discharge. CLASSIFICATION OF COMPRESSORS

RECIPROCATING COMPRESSORS:Reciprocating compressors generally, employ piston-cylinder arrangement where displacement of piston in cylinder causes rise in pressure.

Centrifugal Compressor:A centrifugal compressor is a radial flow rotodynamic fluid machine that uses mostly air as the working fluid and utilizes the mechanical energy imparted to the machine from outside to increase the total internal energy of the fluid mainly in the form of increased static pressure head.

DESIGN ASPECT

SL no.SECTIONWORKING1Application/job section.Structure the tenders and prepare the offer to suit the customers requirement.2Execution sectionAfter getting orders. The section prepares departmental purchase indent (DPI), bill of material, Drawings and issue to respective section for the further actions.3Estimation section As pre scope of supply, this section estimates the involved cost (material + manufacturing cost).4Electrical section It estimates the price of prime mover. 5Instrumentation sectionIt prepares the offer for required instruments.

OPERATION INVOLVED IN DEIGN ASPECT

BALANCING: Unwanted material, developed in the components due to wrong casting, blow holes, wrong machining are called unbalanced mass.These unbalance mass must be removed on the balancing machine within the permissible limit either by grinding or welding.

PROCESS OF ASSEMBLY

TESTING

NPSH TEST

COMBINATION OF PUMPS

MANUFACTURING DEPARTMENT

PUMP & COMPRESSOR PLANT (PCP)This section mainly handles the assembly, testing, packing & dispatching of centrifugal pumps, reciprocating pumps reciprocating compressors.FEEDER:

This section consists of four bays. This is the section where preassembly working are done. In this section all machining, fabrication & heat treatment operation are carried out.

**BAY-1**

Bay is the place between two long walls on which rail is situated and overhead Crain is running. Crain is used to carry the heavy machine components from one place to another. Bay-1 is heavy machine shop. The machine available in the BAY-1 are:Vertical borer machine Plano Milling: Horizontal Boring machine Cylindrical grinderRadial DrillCentre lathe Vertical Turret lathe

****BAY-2***

This is light machine shop which mainly contains Centre Lathe, Production lathe, Small size Radial Drilling machine, Boring machine and turret lathe. In this shop mainly small size component are made like impeller of centrifugal pump and shaft keys, bushings cutting of connecting rod. ****BAY-3***This is fabrication shop where beds for pumps & compressor are fabricated. ***BAY-4***Bay-4 has welding machine shop along with two main cutting machines.Bend saw cutting machineProfile cutting machine

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