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QUALITY CONTROL

QUALITY CONTROL. QUALITY : PROJECTS THE IMAGE OF CORPORATION , GOVERNS PRESTIGE CONTROL : SPECIFICATIONS MANUFACTURING ACTIVITY : BASE STOCKS – RAW MATERIALS – ADDITIVES PROCESS CONTROL FINISHED PRODUCTS CONTROL – LUBES, GREASES, SPECIALTIES

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QUALITY CONTROL

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  1. QUALITY CONTROL

  2. QUALITY :PROJECTS THE IMAGE OF CORPORATION , GOVERNS PRESTIGE CONTROL :SPECIFICATIONS MANUFACTURING ACTIVITY : BASE STOCKS – RAW MATERIALS – ADDITIVES PROCESS CONTROL FINISHED PRODUCTS CONTROL –LUBES, GREASES, SPECIALTIES FUELS (OTHER THAN AVIATION) & SOLVENTS AVIATION FUELS (ATF) PILFERATION AND ADULTERATION CHECK PROGRAMME MARKETING DISCIPLINE SCHEME FOR FUELS AND LUBES VIGILANCE AND RELATED AGENCIES QUALITY IS EVERYBODY’’S BUSINESS QUALITY CONTROL ACTIVITY

  3. Customers Retail Direct Sales LPG

  4. Role of QC at various stages • Manufacturing : • Testing and reporting for products against specs. • Seek explanation for deviations. • Recommend appropriate remedial action, • Examine amendments to specs. • Set new specifications/ standards in conjunction with R&D, user depts. Industry and Ministry. • Seek / recommend time-bound action plan for disposal of off-spec products in consultation with R & D.

  5. Storage, Handling & Distribution: Regular QC audits / inspections. Practices to conform to IQCM. Responsibility of locations. Recommendations/ suggestions by QC for time-bound action plan for implementation. Seek compliance report. Reactivate defunct labs in locations Up gradation of lab facilities. New QC labs at other locations. Role of QC at various stages

  6. Procurement stage: Testing of raw materials / additives and advising outcome. Setting guidelines for handling deviations. Incorporate appropriate penal clauses in purchase contracts. Evolve / amend specs in conjunction with R&D and user Departments. Role of QC at various stages

  7. Vendor stage: Audit / inspection of re-packers. Audit / inspection of suppliers. Evolve penal clauses. Role of QC at various stages

  8. ISSUES • Manpower for Labs. • Existing vacancies. • Reporting structure of Labs. • Accountability of custodians. • Quality cushion from Refineries as per Industry Acceptance Manual. • Interface management at locations. • Sample discipline. • Implementation of Multi Discipline Safety Audit at Terminals. • Storage Constraints: • Tank Cleaning • Product quality during dry out situations.

  9. STANDARD METHODS OF TESTS FOR PETROLEUM PRODUCTS • AMERICAN SOCIETY FOR TESTING AND MATERIALS (USA) ASTM SECTION 05.01 … ASTM D 56 - D 2596 SECTION 05.02 … ASTM D 2597 - D 4629 SECTION 05.03 … ASTM D 4636 - D 5483 • INSTITUTE OF PETROLEUM, LONDON IP STANDARDS VOL I .. 1 TO 317 VOL II .. 318 TO 429 • INDIAN STANDARDS IS 1448 P-1,2,3…. • OTHER STANDARDS i. FEDERAL STANDARDS ii. DIN STANDARDS iii. ISO STANDARDS iv. JIS STANDARDS

  10. QUALITY CONTROL : NON-AVIATION PETROLEUM PRODUCTS • QUALITY CONTROL BEFORE SHIPMENT: REFINERIES • QUALITY CONTROL PRIOR TO RECEIPT: PRE-DISCHARGE TESTS • QUALITY CONTROL AFTER RECEIPT : TERMINALS / BULK PLANTS - BATCH FORMATION TESTS - MONITORING CHECKS FOR STORAGE STABILITY - FILL POINT SAMPLES , DAILY • QUALITY CONTROL CHECKS : DEPOTS - CRITICAL TESTS - MONTHLY MONITORING CHECKS - FILL POINT SAMPLES - QC RECORD • QUALITY CONTROL CHECKS AT RETAIL OUTLETS MS -: FILTER PAPER TEST MS & HSD -: DENSITY-TEMP. MEASUREMENT *************** MS/HSD - MOBILE LABORATORY - CLINICAL TESTS

  11. ISI (BIS) PROPRIETORY COMPANY STANDARDS ALL FUELS & SOLVENTS MEET ISI SPECS. PETROL - IS 2796 – 2000* SKO - IS 1459 - 1974 HSD - IS 1460 - 2005 LDO - IS 1460 - 2000 IFO - IS 1593 - 1982 SOLVENT 1425 - IS 1745 - 1978 SOLVENT 2445 - IS 1745 - 1978 HEXANE - IS 3470 - 2002 ATF - IS 1571 - 2001 FINIT - IS 1824 – 1978 * WITH AMENDMENT OF 2005 SPECIFICATIONS

  12. INDIAN STANDARD SPECIFICATION FOR BS-II MOTOR GASOLINE , IS:2796–2000

  13. *LIMITS FOR GASOHOL # MAY TO JULY IN CENTRAL & NORTHERN PLAINS

  14. BS-III SPECIFICATION FOR MOTOR GASOLINEIS:2796,2000

  15. *LIMITS FOR GASOLINE-ETHANOL BLENDS

  16. INDIAN STANDARD SPECIFICATION FOR BS-II DIESEL FUELS IS:1460–2005

  17. BS-III SPECIFICATION FOR DIESEL IS:1460,2005

  18. INDIAN STANDARD SPECIFICATION FOR KEROSENE IS:1459–1974 NOTE :* 22 MIN FOR RAILWAYS / DEFENCE # 0.2 MAX FOR DEFENCE

  19. IS SPECIFICATIONS FOR FUEL OILS IS : 1593 - 1982 NOTE : 1. NORMAL GROSS CALORIFIC VALUE 10,000 CAL / gm 2. FUEL OIL FOR MARINE USE – DENSITY 0.99 MAX.

  20. QC CHECKS AT POL LOCATIONS • QC CHECKS ARE CARRIED AT VARIOUS STAGES OF STOCK HANDLING IN POL OPERATIONS • DURING RECIEPT • DURING STORAGE • DURING DISPATCH

  21. QC CHECKS DURING RECIEPT • Receipt Thru P/L,Ocean Tankers : • UML composite sample from nominated tank to be drawn jointly – labeled ,sealed and retained • Above to be discarded , in case A/R sample meets specifications

  22. QC CHECKS DURING RECIEPT contd • Samples(from top and bottom sample cock ) to be tested for Test A every 10 minutes for half an hour and there after hourly (FILM) • Repeat above in case of stoppage & resumption of pumping • Density variation to be +/- 3.0 • Two litres of retention samples during commencement , middle and end of discharge

  23. QC CHECKS DURING RECIEPT contd • TMB sample to be drawn after min. 1 hour • In case of SKO , additionally flash point test on top sample to be carried out. • Composite sample of SKO to be retained for 3 months

  24. QC CHECKS DURING RECIEPT contd • TMB samples to be taken from tanks accommodating interface and tested for density to ensure homogeneity

  25. QC CHECKS DURING RECIEPT contd • Receipt Thru T/W : • SKO receipt : Top sample after receipts to be tested flash point , density and retained for 30 days • All level sample to be drawn and tested for colour visual , for grade identification

  26. QC CHECKS DURING RECIEPT contd • Receipt thru Unconnected TW : All sample to be drawn and tested for full specification

  27. QC CHECKS DURING RECIEPT contd • Receipt thru T/T’s: Check for presence of water • Sample from each compartment to be subjected to Test A

  28. QC CHECKS DURING RECIEPT contd • Receipt by drums : Samples to be taken on cube root basis

  29. QC CHECKS DURING STORAGE • All level sample of first parcel of new tank/ grade change over to be drawn for batch formation tests. • Bottom sample of LSHF HSD tanks after cleaning and every fortnightly to be tested for Copper strip corrosion and in case of water bottom tanks, fortnightly Test E to be carried • SKO tank with no fresh receipt for 7 days : top sample to be tested for Density/FP • To repeat the same every 7 days till fresh receipt .

  30. QC CHECKS DURING STORAGE contd • Test E to be carried on water sample of water bottom tanks on fortnightly basis

  31. QUALITY MONITORING- Monthly • Composite sample from each tank • MS - test D • Naphtha – test F • SKO – test G • HSD/LSHF/HFHSD/LD – test H • FO – test I • Ethanol – Table 1 of QCM of gasohol

  32. QUALITY MONITORING- Monthly contd • In case of NO receipt for 3 months, UML for Vertical, All level from Horizontal tanks to be drawn and tested for batch formation tests.

  33. QC CHECKS DURING DISPATCH • Ocean Tanker loading : UML of shore tank drawn and retained • Samples to be tested for Test A every 10 minutes for half an hour and there after hourly

  34. Pipeline dispatches • Samples to be tested for Test A every 10 minutes for half an hour and there after hourly • Repeat above in case of stoppage & resumption of pumping • Density variation to be +/- 3.0 • Two litres of retention samples during commencement , middle and end of discharge

  35. Pipeline dispatches contd • UML of Shipping tank to be drawn jointly and retained till batch is established • Hourly top & bottom samples drawn , test A done

  36. T/W dispatches • Product wise sample is drawn from T/W filling line before each shift and when there is switch over for test A • SKO T/W density checks are carried

  37. T/T dispatches • Product wise sample is drawn from T/T filling line before each shift and when there is switch over for test A and density checks • In automated locations, sample is drawn from delivery line closer to filling bay. • 4 x 1 litres - MS , 2 X 1 Litre – HSD (MDG 2005)

  38. T/T dispatches contd • Water dips of tanks to be taken (MDG) for remedial measures • SKO to be released after visual ,density and flash point checks • Presence of furfural ,blue dye ,marker, Ethanol to be check before release.

  39. Retention of sample- T/W&T/T • MS/HSD /SKO samples – For 15 days

  40. PROCEDURE FOR TANK TRUCK AND TANK WAGON GRADE CHANGE OVER NOTE : MAINTAIN RECORD OF EACH T/W AND T/T GRADE CHANGE OVER

  41. MULTI PRODUCT PIPELINE TRANSFER ,INTERFACE ACCOMODATION (REVISED)

  42. NOTE :* INTERFACE OF FRONT AND REAR END TOGETHER NOT TO EXCEED 2% OF PRODUCT RECEIVED IN THE TANK. – IN CASE OF HSD/LDO CARE TO BE TAKEN TO PROTECT FLASH POINT OF LDO. ** IN CASE INTERFACE OF MORE THAN 1 % MS/SK IS ACCOMMODATED IN MS TANK , COMPOSITE OF U/M/L SAMPLES TO BE SENT FOR B/F TEST AND PRODUCT RELEASED ONLY IF IT MEETS SPECS.

  43. Test Category • Test A : Appearance , density @15 deg C • Test B : Batch formation tests • Test C: Presence of water • Test D : Density , distillation , colour , Existent gum • Test E : Sulphide on water • Test F: Density , distillation , colour , ROE

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