BHARAT PETROLEUM CORPORATION LIMITED, MANMAD INSTALLATION

Comprehensive Learning Report

Name and Address of Bharat Petroleum Corporation Limited Panewadi, Nandgaon -Manmad Road,
Establishment P.O.Manmad, Dist.Nashik, 423104

Name of Apprentice Mr. Krishna Mhasu Umbare

Trade Mechanical Engineer
Registration Number WMHD006180600774
Apprenticeship Period 16 Nov 2020 To 16 Jan 2022

About BPCL Manmad Installation (MI) -

 BPCL Manmad Installation is one of the major marketing installations of BPCL. The area of
BPCL MI is 233 Acres and commissioned in year 1998. It is receiving product form BPCL
(Mumbai Refinery) via dedicated pipeline called as MMBPL. The product received are Motor
Spirit (MS), High Speed Diesel (HSD) and Superior Kerosene Oil (SKO).
 The total storage capacity is 367000 KL.
 There is 16 no. of tanks.
 Largest tank is having Dia. of 65 meter and capacity 57000 KL.
 Automation used in BPCL MI is Honeywell.

Petroleum Products in BPCL MI and its Properties

1. Motor Spirit (MS)

2. Superior Kerosene Oil (SKO)
3. High Speed Diesel (HSD)

1) Motor spirit (MS)

Class A
Colour Clear Orange
Density Range 700 kg/m3 to 750 kg/m3
Flash Point Having 230 C

2) Superior Kerosene Oil (SKO)

Class C
Colour Colourless
Density Range 750 kg/m3 to 800 kg/m3
Flash Point 230 C to 65 0 C
3) High Speed Diesel (HSD)

Class B
Colour Clear Pale Yellow
Density Range 800 kg/m3 to 850 kg/m3
Flash Point 55 to 66 0 C

BPCL Transfers the product to the customers in three ways-

1. Pipeline transfer (PLT)- [Customer- HPCL and IOCL]

2. Rake Transfer
3. Tank Lorry transfer

Wagon Gantry- It consist of 2 spurs on which rake is place.

Spur 1 – Product filling MS, SKO, HSD

Spur 2 – Product filling MS AND HSD

Rake – It contains 50 wagons.

The wagon has 2 types

 BTPN- Bogie Tank Petrol and Naphtha

 BTFLN- Bogie Frameless Tank Wagon

Tank Wagon filling Process-

1. As per the advice from upper level manager load is assign for rake.
2. According to that indent is register on FOIS.
3. Railway confirm the load and provide MS fit wagon According to MS load.
4. Wagon security take the round of wagon gantry and after that rake is placed in the wagon
gantry area.
5. Wagon gantry staff checks the emptiness of wagon.
6. After that in control room the rake is register into the system and make it authorized to fill
the load.
7. Wagon officer take the round of wagon before filling the wagons.
8. After that rake filling start. This rake filling is done in 2 or 3 lots depend upon gantry.
9. After filling, wagon officer went into the gantry area with paste on slip, gave this paste on slip
to the gantry worker, and taken the deep of each wagon with technician and gantry worker.
 10. Gantry officer checked the quantity, product and wagon id with system generated document.
11. After taking deep sealing is done. Further that Rake release from wagon gantry with
necessary documents.
12. Rake release from system.

Document Require For Tank Lorry Filling Various Documents Required for Tank Lorry

 Calibration
 Explosive License
 Fitness Certificate
 PESO Certificate
 Insurance Certificate of Vehicle, Driver and Cleaner
 RTO Endorsement
 PUC
 Hilly Permit
 Safety Check
 Calibration: Done by Department of weights and measure (State Government)

Tank Lorry Safety Checks and Calibration –

Quality of product define by its properties like Density and Temperature.

Because of temperature changes Density of Product changes to standardize the temperature

changes as per ASTM (American Standard Testing of Material) theory of 15 0 C is used.

Density measuring apparatus: Hydrometer (different ranges for different products)

Sampling of Products and Sampling Instruments

Instrument:

 Sampler thief – Bottom Sampling

 All Level Sampler – At any Level

Sample Container:

 Aluminium- Sealing, 5% to 10% space is given for expansion of product called “Breathing
Space”.
 Kept in wooden box with seal.
 Note: Aluminium containers are not use for Ethanol Sampling instead of that Glass Container
are used.

Samples:

Classify on level of sample taken:

 a. Top sample: 15cm below top surface in tank and from sampling cock at top of pipeline
b. Skim Top Sample: Sample Skimmed from surface of product in tank.
c. Upper Sample: Level of (1/6) th from Top
d. Middle Sample: Level of (1/2) th from top
e. Lower sample: Level of (5/6) th from top

Composite Sample:

1. Vertical Tank

 Upper, Middle and Lower sample for product depth above 4 meters.
 Upper and lower sample for product depth between 2 meters and 4 meters.
 Middle Sample for product depth below 2 meters.

2.Horizontal Tank: Composite Samples shall be taken at all level.

Bottom Sample: Lowest point at which sample is taken in tank and bottom of pipe line.

Sampling Procedure:

Done as per IS 1447 (Method of Sampling of petroleum and its products.)

Basic Principle of sampling- It’s a truly repetitive sample for whole product.

PCK: Pipe line Compatible Kerosene use between two different products in Pipe-Line. It can be blend
on advice given by quality control lab.

Valves and Machineries-

 Tank Inspection: Done as per OISD standard

 Valve Inspection/Testing/Servicing
 PV Valve Operation, Testing.
 Tap Point: Pumping and storage
 Plug valve: Quick shut valve (3” to 5” valve)
 Gate Valve: Vertical thick plate with vertical moment (18” to 24”)
 In petroleum industries mostly, Centrifugal Pumps are used for continuous flow.
 Fire Engines are always Centrifugal pumps
 Vane pump are used for high velocity.

Vibration Analysis of Product Pumps-

In BPCL MI centrifugal pumps are used to pump the petroleum products. A centrifugal pump is a
rotodynamic hydraulic machine that transforms the mechanical energy of the impeller into kinetic or
pressure energy by transmitting it to an incompressible fluid.
Vibration Measurement Points-

The vibration of the shaft, impeller and bearing can all be measured by mounting the vibration
meter on the bearing housing of the pump in the horizontal, vertical and axial direction.

Pump and Motor Alignment

Motor- Pump alignment is the process of aligning the shaft centre lines between a motor and a
pump. The motor is the prime mover, transforming power to the pump by the use of a coupling.

There are three methods of alignment

1. Visual Line-up
2. Straightedge/Feeler Gauge
3. Dial Indicator

1) Visual Line Up

It is the most common method of alignment. In the initial installation, technician follow this process
to align the shaft of motor and pump.

2) Straightedge/Feeler Gauge

Straightedges are used to determine the offset between coupling halves. Corrections are made
under all four of the machines feet. Feeler gauges or taper gauges measure the gap between
coupling halves at the bottom and top of the coupling.

3) Dial Indicator

This method uses two dial indicators mounted exactly 180 apart to take shaft-to-shaft readings. Both
parallel and angular misalignment may be compensated for at the same time. This method allows
the couplings to remain attached, as the shafts must move together.

General Maintenance of Motor Bearing-During the time of maintenance of bearing following

procedure was followed in BPCL.
 1. When the motor arrives for repair technician inspect every bearing especially if a VFD
controlled it.

2. Technician inspected the outside and inside of the bearing.

3. If the bearing is ok then technician just removed the dirt from bearing, providing lubrication
and placed on its dedicated place.

4. It bearing found not ok then technician go for replacement.

Mechanical Pipeline Equipment’s-

Strainer – Strainer is the important part of pipeline system. After 3 months strainer gets cleaned of
Lorry gantry, wagon gantry and pump house.

Process followed for cleaning the strainers-

Firstly, removed all bolts, removed the net of strainer, cleaned the strainer with brush and high-
pressure water and fitted it again to the dedicated location by providing proper greasing to the
bolts.

PD Meter-Positive Displacement flow meter are the only flow measuring technology to directly
measure the volume of fluid that passes through the flow meter. It achieves this by trapping pocket
of fluid between rotating components housed within a high precision chamber.

Air Eliminator-An air eliminator is a segment of piping which attaches to a main pipe to trap and
release air, fitted ahead of flow meters in a pipeline so that air will not be measured and a more
accurate volumetric reading can therefore be taken.

Mass Flow meter- A mass flow meter, also known as an inertial flow meter is a device that measures
mass flow rate pf fluid travelling through a tube. The mass flow rate is the mass of the fluid traveling
past a fixed point per unit time.

Fire Fighting Equipment’s

There are various types fire extinguisher used in BPCL

Portable fire extinguisher-It is available with different types i.e., A, B, C and also available in various
sizes like 2kg, 9kg, 25kg, 50kg, 75kg etc.

Water extinguisher- In BPCL MI terminal water extinguisher ae located all over the plant with foam
barrel.

Foam extinguisher/ Foam Monitor -This is place in front of tanks, above the tanks and most
hazardous area like lorry gantry, wagon gantry, Pump house area. It has two types Low expansion
and high expansion. Generally high expansion foam is used

Carbon dioxide extinguisher-This type is mainly used for electrical fire.

Dry chemical extinguisher- It is called as DCP. It contains dry chemical powder with high pressure
gas cartridge like carbon dioxide or nitrogen to expel the dry chemical.

Hose Pipe- The fire-hose is a connecting link between the water supply and the fire, and of all
firefighting equipment, it is the most essential.

HVLR system- It is also called as High-Volume Long-Range monitor. Which has special application
monitors, suitable for high volume applications from a safe distance, ensuring safety of personnel.

Soft Skills Training Through “GuruZ” app (Chocoed App):

About GuruZ app:

Soft skills refer to the personality traits, behavior and interpersonal skills that are used to interact
with other people. They enable’s peoples to control their environment, work effectively and
harmoniously with others, perform well and achieve their goals. Thus, soft skills developments are
important, especially in the corporate world. But, because soft skills are highly transferable or
versatile and not usually tied to specific professions or people, they are also very much applicable in
different aspects and situations in the real world and the personal front too.

What is soft skill:

Soft skills are personal attributes that influence how well you can work or interact with others. These
skills make it easier to form relationships with people, create trust and dependability, and lead
teams.

In essence, they are essential for your success in the workplace, your company’s success and your
personal life.

Most interaction with other people requires some level of soft skills. At a company you might be
negotiating to win a new contract, presenting your new idea to colleagues, networking for a new job
and so on. We use soft skills every day at work and developing these soft skills will help you win
more business and accelerate your career progression. On the other hand, a lack of soft skills can
limit your potential, or even be the downfall of your business. By developing strong leadership,
delegation, teamwork and communication abilities, you can run projects more smoothly, deliver
results that please everyone, and even positively influence your personal life improving how you
interact with others.

Soft Skills Learned-

Communication, Social and People Skills

Organization

Teamwork skills and collaboration

Punctuality
Logical and critical thinking

Creativity

Emotional intelligence

Interpersonal Communication

Adaptability

Friendly Personality