Bharat Heavy Electricals Ltd.

AN GOVERNMENT OF INDIA UNDERTAKENINSULATOR PLANT, JAGDISHPUR

(AMETHI) U.P.

Prepared by:

Bhupendra Kumar Shukla

Reg. No: 11205580

Roll No: RM1204B43

School of Mechanical Engineering

Lovely Professional University, Jalandhar

About the Company 1964 Established Heavy Electricals (India) Limited

1972 In July the operation of all four plants were integrated

1974 In January Heavy Electricals (India) Ltd. Merged with BHEL.

BHEL is largest engineering manufacturing enterprises in India in the energy related/ infrastructure sector, today BHEL was established more than 50 Years ago, ushering in the indigenous Heavy Electricals Equipment in India- a dream that has been more than realized with a well- recognized track record of performance. The company has been earning profit continuously since 1971-72 and paying dividends since 1976-77.

2012 The Hon’ble President of India, Shri Pranab Mukharjee, presenting the National Energy Conservation Award 2012 to Mr. B. Prasad Rao, Chief & Managing Director (CMD), BHEL.

2014 BHEL bags India Today Best Maharatna PSU Award for Global Presence & Innovation

Trophy conferring Maharatna status on BHELfrom Hon’ble President of India in recognitionof company’s consistent high performance

Sh. R. Krishnan, Director (HR) BHEL wasconferred NIT-Trichy’s Distinguished AlumnusAward by the former President of India,Dr. A.P.J. Abdul Kalam as part of GoldenJubilee celebrations of the Institute

BHEL PRODUCT PORTFOLIO, JAGDISHPUR

The Product portfolio divided into three categories:

1. L T Type insulators

2. Disk Type Insulators

3. CERALINS

L T TYPE INSULATORSa) Pin Type (10KN, with distance of

230/280/320mm)b) Guy/Stay/Strain (53/89/110KN with

distance of 42/52/65/72mm)c) Post/Suspended Type

Disk Type InsulatorCode Strength(KN)

01 160 (CD-280 mm)

02 70/90/120

03 45

06 120(CD-280 mm)

08 210

11 120

13 120

14 70/90/120

15 70/90/120/160

17 70/90/120

BHEL JAGDISHPUR INSULATOR PLANT

Insulator Plant, Jagdishpur was inaugurated on March 03rd, 1984 by the Hon’ble Prime Minister of India Late Smt. Indira Gandhi, as 11th manufacturing unit of BHEL in Amethi District, 78 Km away from Lucknow on Lucknow-Sultanpur National Highway. BHEL’s glorious experience in the ceramic field with technical collaboration with M/s. NGK, Japan, the world leader in Insulator Technology, set the pace for the commissioning of this plant. This unit has been provided with the most modern and sophisticated facilities.

BHEL's Heavy Electrical Plant, Bhopal 2x363 MW Gas-based Power Plant, OTPC-Palatana

MANUFACTURING OF INSULATORS

1. For Manufacturing of Disc InsulatorStorage Slip House Jiggering Unit Finishing Unit Glazing Unit Firing Unit Assembly Unit Testing Unit Dispatch Unit

2. For Manufacturing of Hollow Bushing Storage Slip House Jiggering Unit Finishing Unit Glazing Unit Firing Unit Assembly Unit Testing Unit Dispatch Unit

Flow Process of Insulators

Process Flow Chart of Disc Insulator

Disc Insulator

Hollow Bushing

Disc and Hollow Insulators both are manufactured by the Cake

1. SB CAKE for the Disc Ins.2. AB CAKE for the Hollow Bush

Slip House

•Ball Mill(mixing)•3 Ton, 1760 ltr for 16 Hrs. + 2 Ton 3800 ltr for 2 hrs.

Tank Storage

•Cake Formation•Hardness (22±2) •1.5 to 2.5 hrs•128*2= 256,100*4=400

•So Total 856 Piece in one shift

•Remove Moisture

Pugging

•Remove Air Gap•Blank Formation•Pressure 720mm Hg•Blank Φ180•Length=220

Jiggering

•Making Shape of Cell•Primary Die•Secondary Die

Chain Dryer

•Remove Moisture through CD

•2.5 Hours

Finishing

• On Lathe Machine

Tunnel Dryer

• Moisture Removal • On diffreent

Tempreture Zone• 35°Ϲ-45°Ϲ-62°Ϲ-

103°Ϲ-62°Ϲ

Glazing

• Drying(Dust Collecter)

• Painting• Marking(Stamp of

BHEL)

Kiln

• At 1200°Ϲ for 58 hours.

Testing

• Hydraullic Testing of 220 Kg for Head Test.

Time Testing (TCT)

• 15min Cold• 1min Hot• Temp. diff >70°Ϲ

Assembly

• Cell+Cap• (spacer)+• Cement+Pin

Spray

• Betromens Paint• for the head joint

Steam Testing

• To attach cement for 4 hrs

• Dip in Cold Water for 72 hours

• 30<steam<62°Ϲ

Mechanical Testing

• 30-32 Piece • tensile Load of 100 Kg• Cap and Pin Testing

Electrical Testing

• 32000 Volt Current Supply• Total 1,56,000 Volt Supply for

the cell testing

Packing

• Assembly Product packing

Complete Flow Process

Ball Mill Machine Sanding Glaze Brown Glaze

Slip House

Raw Material for the Cake is Mixed in the Mixing Tank under Slip House Cake Formation 80% of the Moisture has been removed

through this.

Jiggering Plant

Pugging MachineUnder this the Blanks are formed though the Pugging machine, the remaining 22% moisture has been removed. D= 80mm L= 220mm

PUGG MILL

Jiggering Plant Under this the formation of Insulator has been doneThe two dies Primary and Secondary dies

Model Drying Chamber for Hollow Bushing Dust Collector, for the Insulators

Glazing Machine for Painting

GLAZING PLANT

Stamping on Cell Shatal Kiln Shatal Kiln at 1200 deg-cen

STAMPING & FIRING UNIT

Hydraulic Test Electrical Testing, 156000Volt

Mechanical Testing 100KN Tensile Force

ASSEMBLY & TESTING

Packing & Dispatch

Thank You