PRESENTATION

ON VOCATIONAL TRAINING
AT
BHARAT 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 BPCL
1. CENTRIFUGAL PUMPS
2. RECIPROCATING PUMPS
3.RECIPROCATING COMPRESSORS
4. GAS CYLENDERS

HIGH PRESSURE INDUSTRIAL CYLINDER

CNG CYLINDERS

BPCL MAIN CUSTOMER

REFINERIES AND PETROCHEMICALS SECTOR
Indian Oil Corporation limited
Hindustan Petroleum corporation Limited
Bharat Petroleum Corporation limited
OIL AND GAS SECTOR
Oil and Natural Gas Corporation Limited
Gas Authority of India limited
Oil India Limited
NUCLEAR POWER
Department of Atomic Energy
Bhabha Atomic Research Centre
Nuclear power Corporation Limited

GAS CYLINDER PLANT

Cylinder 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
1. Cutting of pipe
2. Doming
3. Bottom forming
4 Necking

5.Heat treatment of cylinder

Hardening
Tempering

6.Machining operation
Turning and Facing
Neck ring is jammed by cod press
Drilling
Reaming

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

9: Shot blasting and stamping

10: Color coding

Color 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
1: Oxygen
2: carbon dioxide

CYLNDER COLOUR
Black
Black (neck) + white (body)

3: Air

French blue

4: Organ

Peacock blue

5: Nitrogen

French grey (body) + Black band (neck)

PUMPS & COMPRESSORS DIVISION

The PCD consists of1. Design Department
2. Manufacturing Department
THEORETICAL ASPECTS
PUMPS - 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 PUMPS
Rotodynamic type (e.g. centrifugal pumps)
Positive displacement type (e.g. reciprocating pumps)
CENTRIFUGAL PUMPS
IMPORTANT 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 PUMPS
RECIPROCATIONG 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.

SECTION

WORKING

Application/job section. Structure the tenders and prepare the offer

to suit the customers requirement.

Execution section

After getting orders. The section prepares

departmental purchase indent (DPI), bill of
material, Drawings and issue to respective
section for the further actions.

Estimation section

Electrical section

As pre scope of supply, this section

estimates the involved cost (material +
manufacturing cost).
It estimates the price of prime mover.

Instrumentation
section

It
prepares
instruments.

the

offer

for

required

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. Bay1 is heavy machine shop. The machine available in the BAY-1 are:
Vertical borer machine
Plano Milling:
Horizontal Boring machine
Cylindrical grinder
Radial Drill
Centre 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 machine

Profile cutting machine

THANK YOU