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A STUDY OF MANUFACTURING OF INSULATORS & PRODUCTION PROCESS OF ELECTRONIC
PRODUCTS AT
BHARAT HEAVY ELECTRICALS LTD. INSULAOTR PLANT, JAGDISHPUR (AMETHI)
UTTAR PRADESH
Submitted By:
Bhupendra Kumar Shukla Reg. No- 11205580 B.Tech- Mechanical Engineering Lovely Professional University Jalandhar (Punjab)
Under the guidance of:
Vijay Sharma Sushil Kumar Sr. Manager (Production) Training coordinator Bharat Heavy Electricals Ltd. School of Mechanical Eng. Jagsidhpur- Amethi (U.P) Lovely Professional University, Jalandhar (Punjab)
SUMMER TRAINING REPORT IN PARTIAL FULFILLMENT OF THE AWARD OF FULL TIME BACHELOR OF TECHNOLOGY (2012-16)
SCHOOL OF MECHANICAL ENGINEERING
LOVELY PROFESSIONAL UNIVERSITY, JALANDHAR
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STUDENT CERTIFICATE
Certified that this report is prepared based on the summer training project undertaken by me in Bharat Heavy Electrical Ltd. From 01.07.2015 to 31.07.2015, under the able guidance of Mr. Vijay Sharma (Sr. Manager) in partial fulfillment of the requirement for award of degree of Bachelor in Technology (B. Tech – ME) from Lovely Professional University, Jalandhar (Punjab). Date: __/__/____ …………………… …………………. …………………. Bhupendra Kr. Mr. Vijay Sharma Shukla (Sr. Manager- Production) BHEL- Jagdishpur (U.P.)
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FACULTY CERTIFICATE
Forwarded with a summer training report on “A Study on Manufacturing of
Insulators & Production Process of Electronic Equipment’s at Bharat Heavy Electricals Ltd. Submitted by Bhupendra Kumar Shukla, Enrollment No. 11205580, and student of B.Tech- ME IIIrd Semester (2012-16). This training is in partial fulfillment of the requirement for the degree of Bachelor in Technology from Lovely Professional University, Jalandhar (Punjab). …………………………….. School of Mechanical Engineering Lovely Professional University Jalandhar
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CERTIFICATE
This is to certify that Mr. Bhupendra Kumar Shukla, student of B.Tech- ME (3rd Year), Lovely Professional University Jalandhar has undergone his Summer Training in Production/ Manufacturing department of Insulator Plant (IP) of Bharat Heavy Electricals Limited Jagdishpur from 01.07.2015 to 31.07.2015 During this period I found him to be very co-operative, sincere and hard working. I wish to him good luck and success for all his future assignments.
……………………….. Vijay Sharma Sr. Manager (Production/Manufacturing) Bharat Heavy Electricals Ltd. Insulator Plant, Jagdishpur Amethi (Uttar Pradesh)
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ACKNOWLEDGEMENT The satisfaction that accompanies the successful completion of the task would be incomplete without the mention of the people whose ceaseless cooperation made it possible, whose constant guidance and encouragement crown all efforts with success. I am very thankful to Mr. Vijay Sharma (Sr. Manager, Production/Manufacturing) and all the concerning officers and staffs of Bharat Heavy Electricals Limited, Insulator Plant, Jagdishpur (Uttar Pradesh) for their valuable guidance and advice without which I could not have completed my summer training. I also express my sincere gratitude to Mr. Tanuj Kumar Shukla (HR) with whose kind permission this project could shape into success.
Bhupendra Kumar Shukla Reg. No- 11205580 B.Tech- ME (3rd Year) Lovely Professional University) Jalandhar (Punjab)
Last but not the least we would like to thank to the workers of Bharat Heavy Electricals Limited who always gave their full co-operation in helping us to understand what we asked for.
Registered Office: BHEL House Siri Fort, New Delhi– 110049, India Fax: +91-11 26493021, 26492534 Telephone: +91 11 66337000
Web: www.bhel.com
AN INDIAN GOVT. UNDERTAKEN
BHARAT HEAVY ELECTRICALS LIMITED
INSULATOR PLANT– JAGDISHPUR
DISTT– AMETHI (UTTAR PRADESH)
Certificate of Training This certificate is awarded to
Mr. Bhupendra Kr. Shukla (A Student of B.Tech-ME, Lovely Professional University, Jalandhar)
For
Completion of Summer Industrial Training
in
A study on Manufacturing of Insulator & Production Process of Electronic
Equipment's At
Bharat Heavy Electricals Limited, Jagdishpur
From 01.07.2015 to 31.07.2015
For Bharat Heavy Electricals Limited.
( Vijay Sharma)
Sr. Manager
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Contents of the Report
Topic Page No.
CHAPTER-1 .................................................................................................................. 8
Introduction to BHEL ................................................................................................. 8
Corporate Profile ....................................................................................................... 10
History of the Company ........................................................................................... 13
CHAPTER-2 ................................................................................................................ 17
A Unit of BHEL ....................................................................................................... 17
System ...................................................................................................................... 19
Product and Services ................................................................................................ 20
CHAPTER-3 ................................................................................................................ 26
Company Objective .................................................................................................. 26
Power Distribution Plan ........................................................................................... 27
Calibration Lab............................................................................................................................ 28
Ceramic Lab ................................................................................................................................ 29
CHAPTER-4 ................................................................................................................ 30
Major Rivals of BHEL ............................................................................................................. 30
Major Customers of BHEL ..................................................................................................... 31
CHAPTER-5 ................................................................................................................ 33
Manufacturing of Insulators ................................................................................................... 33
Technical Characteristic .............................................................................. 33
Process Flow Chart of Insulator ................................................................. 34
Storage ........................................................................................................... 36
Complete Flow Process ............................................................................... 38
Slip House ..................................................................................................... 39
Preparation of Cake ...................................................................................... 44
Pugging ........................................................................................................... 46
Jiggering- Forming of Disc Insulators ....................................................... 48
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Drying ............................................................................................................ 49
Finishing ........................................................................................................ 50
Inspection- Segregation of Defective Insulators ...................................... 51
Tunnel Dryers (T.D) ................................................................................... 51
Glazing .......................................................................................................... 52
Firing of Insulators (Kiln Section) ............................................................ 55
Assembly Section ......................................................................................... 56
Testing of Insulators ..................................................................................... 58
Packing and Dispatch ................................................................................... 61
CHAPTER-6 ................................................................................................................ 62
References ....................................................................................................... 62
Conclusion ....................................................................................................... 62
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CHAPTER-1 Introduction to 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.
The Vision of BHEL is:
The company is striving to give shape to its aspiration and fulfill the expectations of the country to become global player.
The greatest strength of BHEL is its highly skilled and committed 47,525 employees. BHEL has Installed equipment for over 90,000 MW of power generation for utilities, Captive and Industrial users. Supplied over 2,25,000 MVA transformer capacity and other equipment operating in Transmission & Distribution network up to 400kv (AC & DC).
BHEL manufactures over 180 products under 30 major products groups and caters
to core sector of the Indian economy viz., Power Generation and transmission,
industry, Transportation, Telecommunication, Renewable Energy etc.
Strategic plan 2012 for ensuring a sustainable profitable growth for the company
has been drawn up to enable the company’s turnover to grow from US $ 4 billion
to 10 billion by 2011-12.
“A global Engineering Enterprise providing solutions for a better tomorrow.”
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Supplied over 25,000 Motors with drive Control system to power projects, Petrochemicals, Refineries, Steel, Alluminum, Fertilizer, Cement plants etc.
Supplied Traction electric and AC/DC locos to power over 12,000 KM Railway network. Supplied over one million Valves to Power Plants and other Industries.
The Mission of BHEL is:
34154
4333749510 50156
40338
0
10000
20000
30000
40000
50000
60000
2009-10 2010-11 2011-12 2012-13 2013-14
Turnover(in Crore)
82.50%
9%
8.50%
Sector-wise order Book Outstanding (As at March 31, 2014)
Power Sector Industry Sector International Operation
“Providing Sustainable Business Solutions in the Fields of Energy, Industry &
Infrastructure.”
First it was Incorporated
In 1964 with 3 Plants:
- Hyderabad
- Tiruchy
- Bagalore
Second Generation
Plant were setup In Mid
70’s at
- Jhansi
- Ranipat
- Tiruchy
- Bangalore
- Haridwar
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CORPORATE PROFILE
About
BHEL Embarking upon the 50th Golden Year of its journey of engineering excellence, BHEL is an integrated power plant equipment manufacturer and one of the largest engineering and manufacturing company of its kind in India engaged in the design, engineering, manufacture, construction, testing, commissioning and servicing of a wide range of the products and services for the core sector of the economy, viz. Power, Transmission, Industry, Transportation (Railway), Renewable Energy, Oil & Gas and Defense with over 180 products offering to meet the needs of these sectors. Establishment of BHEL in 1964 was a breakthrough for upsurge in India’s Heavy Electrical Equipment industry. Consistent performance in a highly competitive environment enabled BHEL attain the coveted ‘Maharatna’ status in 2013.
BHEL as a part of Pt. Jawaharlal Nehru’s vision was bestowed with the onus to make the country self-reliant in manufacturing of heavy electrical equipment. This dream has been more than realized and the contribution in nation building endeavor is going to continue likewise. Today, with 20,000 MW per annum capacity for power plant
Power Sector
BHEL is one of the few companies in
the world having capability of
manufacturer entire range of power
plant equipment and has proven
turnkey abilities for executing power
projects from concept-to-
commissioning. The Power Sector
comprises Thermal, Gas, Hydro and
Nuclear power plants.
BHEL:
Supplies steam turbine, generator,
boilers and its auxiliaries up to 800
MW including sets of 600/700/800
MW based on supercritical
technology
Has facility to make thermal set up
to 1000 MW unit size
Supplies hydro turbine and
generators up to 250 MW
Manufacturers
220/235/540/550/700 MW nuclear
turbine generator set
Has proven expertise in plant
performance improvement
through Renovation,
Modernization and Uprating of
variety of power plant equipment
Special knowhow of residual life
assessment health diagnostics and
life extension of plants
Supplied thermal sets have
consistently exceeded national
average efficiency parameters.
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equipment manufacturing, BHEL’s mammoth size of operation is evident from its widespread network of 17 Manufacturing Units, 2 Repair Units, 4 Regional Offices, 8 service centers, 8 overseas offices, 6 joint venture, 15 Regional Marketing Centers and current project execution at more than 150 project site across India and abroad.
BHEL’s Heavy Electrical Plant, Bhopal
The total installed capacity based of BHEL supplied equipment -138 GW in India speaks volumes about the contribution made by BHEL to Indian power sector. BHEL’s 57% share in India’s total installed capacity and 65% share in the country’s total generation from thermal utility sets (coal based) as of March 31,2014 stand testimony to his. The company has been earning profits continuously since 1971-72 and paying dividends since 1976-77 which is a reflection of company’s commendable performance throughout.
BHEL also has a widespread overseas footprint in 76 counties with cumulative overseas installed capacity of BHEL manufactured power plant nearing 10,000 MW including Malaysia, Oman, Libya, Iraq, the UAE, Bhutan, Egypt and New Zeeland.
The high level of quality & reliability of BHEL products and systems due to adherence to international standards by acquiring and adapting some of the best technologies from leading companies in the world including General Electric Company, Alstom SA, Siemens AG and Mitsubishi Heavy Industries Ltd., together with technologies developed in its own R&D centers. Most of its Manufacturing
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units and other entities have been accredited to quality Management System (ISO9001:2008), Environmental Management System (ISO14001:2004) and Occupational Health & Safety Management Systems (OHSAS18001:2007).
2x363 MW Gas based Power Plant, OTPC-Palatana
BHEL has faced challenges with aplomb throughout all the phases of its illustrious journey. Right from its incorporation in a protected market to facing the pressure of a liberalized economy and the current slowdown in the economic environment, BHEL has evolved with transforming its strategies from product manufacturing to market orientation; business excellence through portfolio restricting ushering in the realm of sustained growth through diversification.
BHEL’s greatest strength is its highly skilled and committed workforce of more than 47,000 employees who have been the cornerstone of BHEL’s successful journey. Further, the concept of sustainable development is inculcated in the DNA of BHEL which is evident from its mission statement- “providing sustainable business solution in the fields of energy, industry and infrastructure.” BHEL is also engaging with the society pursuing initiatives aimed at community Development, Health & Hygiene, Education, and Environment Protection, Disaster Management and Talent Up gradation / skill development.
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HISTORY OF 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.
For the manufacturer of a wide variety of products, the company has developed technological infrastructure, skills and quality to meet the stringent requirements of the power plants, transportation, petro chemicals etc. BHEL entered into collaboration which are technical in nature, under these agreements the collaborators have transferred, furnished the information, documentation, including know-how relating to design, engineering, manufacturing assembly etc.
1982 BHEL also entered into power equipment, to reduce its dependence
On the power sector. So it developed the capability to produce a variety of electrical, electronic and mechanical equipment for all sectors, including transmission, transportation, oil and gas and other allied industries.
1991 On 24th December converted into a public Limited company. As per
resolution passed on 23rd December 1991, existing shares of Rs. 1000 each was subdivided into equity shares of Rs. 10 each. 2447,60,000 No. of equity shares of Rs. 10 each allotted for consideration other than cash.
1992 Between January to February the company disinvested 489,52,000
equity shares of Rs. 10 each. During the year 10 thermal sets, 2 gas sets and 11 hydro sets were commissioned. During the year first commercial HUDC transmission line in the country between Rihand and Delhi rated for transmission power at 500KV at 1500MW was respectively completed. As the company completed prestigious contracts in Malta and Cyprus through supply and election of 2 sets of 60 MW thermal sets each.
1994 The company commissioned two sets of 250MW at Maharashtra and
one 500MW once-through tower type boiler at Orissa. During the year
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company established Asia’s largest fuel evaluation test facility at Tiruchi. During the year company under took Indira Sugar Project of Narmada Valley Development Authority in M.P. 3950 KW 18 pole synchronous motors and 6 nos. 3950 KW 6 pole squirrel cage induction motors for ONGC’s Santhal Project.
1997 In May Joint Venture Company named Bhe-Ge Gas Turbine service
Private Ltd. The Public sector Bharat Heavy Electricals Limited (BHEL) has won the national best exporter award for 1995-96, instituted by the Engineering Export Promotion Council of the 8th consecutive year from Madurai. The company undertook supply of 36 MW STG for RIL Sancoale-Goa 2X4MW & 2 & 4.5 MW Generator for Hemavati & Harangi HEP in Karnataka etc.
1998 BHEL has successfully commissioned the 5th Unit 210MW of
Gandhinagar Thermal Power Station the first project undertaken by Gujrat State Electricity Corporation Ltd. In Karnataka BHEL has recently supplied and commissioned hydro-generating equipment for Chunchunakatte HEP (2*9MW) and Bhadra HEP (1*6 MW). Hydro Generating Equipment for the Narayanpur HEP (2*5 MW) has already been supplied and is been installed.
1999 Achieved milestone by synchronous the 5th unit of 210MW capacity at
the Richur Thermal Power Station in Karnataka. Commissioned a desalination plant on turnkey basis in the Gulf of
Mannar in Tamil Nadu. Agreement with Babcock Borsig Power GmbH of Germany for the
manufacturer of ‘once through boilers’ 2000 Signed a memorandum of understanding with Bhakra Beas
Management board to renovate, modernize and upgrade its old hydro-electric power station.
First 150MW hydro generating unit at the Ranjit Sagar Hydro Electric project in Punjab.
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Karnataka Power Corporation has awarded BHEL a Rs. 365 crore contact to set up another 210MW unit at the Raichur Thermal power station.
2001 set up a 5th 250MW unit at Suratgarh thermal power station in western
state of Rajasthan. Commissioned the 1st four hydro-power generating unit at Kurichu
Hydro Electric Project in Bhutan. Awarded the electro-mechanical equipment supply order at a cost of
Rs 540 crore for the Maheshwar hydel project in M.P. 2002 Awarded the exporters award by Engineering Export Promotion
council for the year 1999-2000. BHEL and PFC tie up for joint bids of projects. Receives Chennai Petroleum Corporation Ltd. (CPCL) contact worth
Rs. 174 Crore for a 40 MW gas based co-generation power plant for its refinery project at Chennai.
BHEL in association with IIT Madras launches IT school in Tiruchi. BHEL unit power sector Northern Region Bags OHSAS-18001 &
ISO-14001 certification. Gets 63 crore order from NTPC, 41 cr order from NPC, 16-cr from
Tisco and 2700 cr from NTPC again. Gets Rs 35 cr grid submission project from Rajasthan Electric Board. Launches 4th Solar Power Plant in Lakshadweep. Announces completion of 1000 MW Simhadri thermal power station. Develops automated storage and Retrieval System. 2004 Gets compressor and drive turbine package contact worth Rs. 20-cr Bags Rs 599 cr order to set up 250 MW power project in Maharashtra. Gets Rs 197 cr order from Gujrat Electricity Board, 36 cr from Bhushan steel and from the hydroelectric project in Chhattisgarh. 2005 BHEL and TCS jointly working on marketing initiative ‘Power Pack’ Appoints Dr V Gopalakrishanan as Chief of the BHEL at Tiruchi. 2006 Agreement with IIT Madras for new courses. Bechtel signs Dabhol agreement with BHEL. BHEL target $1.7 bn contract in B’desh.
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2007 BHEL and French company Alstom will together produce 1,50,000 MW of power over the next 10 years.
Appointed Shri N. Gokulram as Part-time official director on the board of the company w.e.f. January 25, 2007.
2008 BHEL, Trichy has secured order worth Rs. 15,000 crore, all time high. BHEL has appointed Shri O.P. Bhutani as Director (Engineering,
Research & Development) on the Board of BHEL w.e.f. December 24, 2009.
2010 BHEL has bagged a Rs 2,665 crore order for supply and installation
of the main plant package for Dainik Bhaskar Power Ltd. 2X600MW coal-based thermal power project at Baradarha, in Chhattisgarh.
2011 BHEL bags Rs 37,289 Million mega Contract for installing
2X600MW Supercritical Thermal sets. 2012 BHEL receives Rs. 9,500 Million mega contact for 1,020 MW
Hydroelectric Project in Bhutan. 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.
2013 BHEL wins India pride award 2013 for Excellence in Heavy
Industries- BHEL wins Rs. 10,230 Million Turbine Generator Package order.
2014 BHEL bags India Today Best Maharatna PSU Award for Global
Presence & Innovation & R&D- BHEL achieves major breakthrough.
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CHAPTER-2
Jagdishpur BHEL-INSULATOR PLANT
‘A Unit of
BHEL’ 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.
With a view to ensure financial viability of Insulator Plant, Jagdishpur the Unit of BHEL planned to diversify to the production of the Industrial
BHEL Insulator Plant, Jagdishpur is the leading
manufacturing of High Tension Porcelain Insulator and
Distribution insulator like Bobbin/Shackle,
Guy/Stay/Strain, Pin, Cap & Pin type Post Insulator in
the country. They are equipped with highly
sophisticated plant and machinery. This division also
offers wear Resistance High Alumina Ceramic Lining
material for Power, Steel, Cement and Mining
Industries as well as a wide range of industrial
Ceramics. BHEL Insulator Plant, Jagdishpur has
attained ISO9001 certification in 1994, ISO144001 and
OHSAS18001 certification in 2002 for its well
establishment systematic production system,
standards, environmental, management and safety
management.
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Ceramic namely “Ceralin” in the year 1989-90. The Ceralin production for commercial use was started in 1993-94. The ceralin was the product being manufactured in BHEL’s Electro porcelain Division, Bangalore and Insulator Plant Jagdishpur got a technologically establishment and commercialized product.
For increasing the production of ceralin BHEL Insulator Plant installed a modern Car Bell type High Temperature Kiln in March, 2009. This HTK (High Temperature Kiln) has firing capacity of 4 to 5 ton of products.
In addition of these:
BHEL Insulator Plant has got certification of merit in
RKBNQA in the year 2008- 09. This shows the
dedication of each individuals of unit for the quality
of works and products.
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PRODUCT & SERVICES
Product BHEL manufactures a wide range of Power Plant equipment and also caters to the industry sector.
Industry
Capacitors
Ceralin
Deslination
Plant
Diesel
Generating Set
Industrial motor
and Alternator
Oil field
equipment
Solar
Photovoltaic
Power
Semiconductor
device
Steel Casting &
Forging
Power
Air Preheaters
Boilers
Control Relay
Panels
Electrostatic
Precipitators
Fabric Filters
Fans
Gas Turbines
Hydro Power
Plant
Piping System
Pulverizers
Pumps
Seamless Steel
Tubes
Soot blowers
Steam
Generators
Steam Turbines
Turbo
Generators
Valves
Compressor
Heat
Exchangers
Switch Gears
Gear Box
Oil Rings
Transmission
Bushing
Dry-type
Transformer
Energy meter
HVDC
Transmission
System
Insulator
Switchgears
Control Shunt
Reactor
Transportation
Electric Rolling
Stock
Electrics for
Transportation
system
Non-
Conventional
Energy Sources
Mini/Micro
Hydro sets
Solar Lanterns
Wind Electric
Generators
Solar Water
Heating
Generators
R & D Products
Fuel Cell
Surface
Coating
Automated
Storage &
Retrievals
Load Sensors
Services
Power
Generating
System
Turnkey Power
Stations
Combined
cycle power
plants
Cogeneration
system
Spares
management
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PRODUCT PROFILE
Thermal Power Plants - Steam Generator, Steam Turbine, Turbo Generators
along with regenerative feed cycle up to 800 MW capacities for fossil-fuel and combined-cycle application, capability to design and manufacture Steam turbine with supercritical steam cycle parameters and matching Turbo Generator of up to 800 MW unit size.
- Condensers, Condensate Extraction Pumps, Boilers Feed Pumps, Valves and Heat Exchangers meeting above requirement of TG sets up to 1000 MW.
Nuclear Power Plant - Steam Generator, Steam Turbine & matching
Turbo-Generators, Condensers up to 700 MW capacity.
- Heat Exchanger - Pressure vessel - Reactor vessels
Gas Based Power Plants - Gas Turbine and matching generators ranging from
25 to 292 MW (ISO) rating. - Gas turbine-based co-generation and combined-
cycle system for industry and utility application.
Hydro Power Plants - Custom-built conventional hydro turbines of Kaplan, Francis and Pelton
type with matching generators, pumps turbines with matching motors-
Services
Consultancy
Services
Erection
commissioning,
operation and
maintenance
services
Modernization
and
rehabilitation of
power stations
Transmission
System
Traction System
Urban
Transportation
System
Industrial System
Industrial Drives
Control System
Spares
Management
Consultancy
Services
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generators up to 300 MW, Bulb turbine with matching generator up to 10 MW.
- High capacity pumps along with matching motors for Lift Irrigation Schemes ( up to 150 MW)
- Electro Hydraulic Microprocessor based Digital governor for conventional turbines.
- Microprocessor based Digital Controller for lift irrigation schemes. - Mini/micro hydro sets with PLC based compact digital governor up to 15
MW - Static excitation system for Hydro generator and motors - Brushless exciter for hydro generators & motors - Special purpose Motor Generator Sets - Spherical (rotary) valves, butterfly valves and auxiliaries for hydro stations.
DG Power Plants - HSD, LDO, FO, LSHS, natural gas based diesel generator power plants, unit
rating of up to 20 MW and voltage up to 11 kV, for emergency, peaking as well as base load operational on turnkey basis.
Industrial Sets - Industrial turbo sets of rating from 7 to 150 MW. - Industrial steam turbine and gas turbine for drive application and co-
generation application. - Reheat steam turbine and matching generators ranging from 120 to 200 MW
captive, utility and combined cycle power plants.
Casting & Forging - Sophisticated heavy casting and forging of creep resistant alloy steels,
stainless steel and other grades of alloy steels meeting stringent international specification for components of sub critical, super critical and ultra-super critical technology.
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Boilers - Steam Generator for utilities, ranging from 30 to 800 MW capacity , using
coal, lignite, oil, natural gas or a combination of these fuels; capacity to manufacturing boilers with supercritical parameters up to 1000 MW unit size.
- Steam generator for Industrial application ranging from 40 to 450 tone/hours capacity, using coal, natural gas, industrial gases, biomass lignite, oil, Bagasse or a combination of these fuels.
1. Pulverized fuel fired boiler 2. Stroke boiler 3. Bubbling fluidized bed combination (BFBC) Boilers 4. Circulating fluidizing bed combination (CFBD) boiler
up to 250 MW 5. Heat recovery steam generator (HRSG) 6. Chemical Recovery boiler for paper industry, ranging
from capacity of 100 to 1000 tons/day of dry solid.
Boiler Auxiliaries Fan
- Axial reaction fans of single stage and double stage for clean air application and dust laden hot gases applications up to 200°Ϲ, with capacity ranging from 40 to 1300 m3/s and pressure ranging from 400 to 1,500 mm of water column.
- Axial impulse fans both clean air and fuel gas application up to 200°Ϲ, and ranging from 25 to 600 m3/s and pressure up to 300 to 700 mm of water column.
- Single and double-section radial fans (plate aero-foil bladed) for clean air and dust laden hot gases applications up to 400°Ϲ, with capacity ranging from 4 to 660 m3/s and pressure ranging from 200 to 3000 mm water column.
Air-Pre-heaters - Tubular Air Preheater for industrial and utility boilers. - Rotary regenerative air-preheaters for boilers and process
furnaces.
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- Large rotary regenerative air-preheater for utility of capacity up to 800MW.
Pulverizers - Bowl mills of slow and medium speed for coal tired thermal
stations with capacity from 18 t/ hour to 110 t/hour catering to 67.5 MW to 800 MW thermal power stations.
Electrostatic Precipitators (ESP) - Electrostatic precipitators of any capacity with outlet emission
as low as 17mg/Nm3 (efficiency up to 99.97%) for utility and industrial applications including Boi mass fired boilers, cement plants, steel plants, soda recovery boilers etc.
Guillotine Gates & Dampers - Guillotine gates with electric. Pneumatic actuator, Size up to
6m height & 7m width (with split) 100% leak proof with seal air.
Soot Blowers - Long retractable soot boilers (LRSB) for travel up to 12.2m - Furnace temperature probe (FTP) for travel length 6.9m and
8.3m - Ash Retractable Non-rotating (LRNR) soot blowers with
forward blowing for Air-heater.
Valves - High and Low-pressure turbine Bypass Valves &hydraulic
system for utility and industrial application
Piping System - Power cycle piping, Constant load Hangers, Variable spring
Hangers, Hanger Components, Low Pressure Piping including Circulating water Piping for power station up to 1000 MW capacity including Super Critical sets.
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Seamless Steel Tubes - Hot-finished and cold-drawn seamless steel tubes with a range
varying form outer diameter of 19 to 133 mm and wall thickness of 2 to 14 mm, in carbon steel and low-alloy steels to suit ASTM/API and other international specifications.
Condenser and Heat Exchanger - Surface Condenser - Feed Water Heater (HP Heater, LP Heater, Drain cooler etc.) - Moisture Separator & Re-heater(MSR) - Live Steam Re-heater - Auxiliary Heat Exchanger for turbo and Hydro Generator - Butterfly Valves (Fabricated/cast body & door) - Flash Tank for thermal & nuclear sets - Generator Air Cooler up to 150 MW STG and GTG up to 9 FA
Pumps - Pumps for various application to suit utilities up to a capacity of
1000 MW - Condensate extraction Pumps
Desalination and Water Treatment Plants - Sewage &effluent Treatment Plants for water re-use and re-cycling
Automated and Control System - Steam Generator/Boiler Control - Steam Turbine Control etc.
Power Electronics - Excitation System - AC drive System - Static Starters
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Transmission System Control - High Voltage Direct Current (HVDC) system - Flexible AC Transmission System (FACTS)
Power Semiconductor Devices - Diodes-Ranging from 1400-4400V/25-2000A
Solar Photovoltaic - Mono/Multi Crystalline Cell (125 and 156mm) - Space Grade Solar Panel - Space Quality Battery
Defense Electronics - Integrated Platform Management System (IPMS) - Integrated Bridge System (IBS) - Machinery Control Room (MCR) Simulator - Weapons Fire Control System, Avionics, radio communication
Product
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CHAPTER-3 COMPANY OBJECTIVE
Objective and
Goals of Insulator Plant Appropriately Integrated Manufacturing with Technology development and
further technology development with marketing.
Thrust on Export Marketing
To maximize the business in Ceramics Area by Business Development. Engineering and Technology Management (Technology acquisition/Technology development/ Job to Job tie up etc.)
To ensure earning on capital employed through efficient and effective use of resources and enhance stake-holders interests.
To produce quality products in the field of Ceramics and attain & sustain a good market share in Ceramics Industry of India.
Product Range Disc Insulator
Products: Porcelain Insulator for 300 KN, HVAC, 160KN HVDC, Post and Pin, Fog and Anti Fog Variety for transmission lines. Insulator for 33KV & 11KV, 420 KN disc insulator has been developed and will be the product of next year. Hollow bushing are the main new product of Insulator plants.
Customers: PGCIL, NTPC, NHPC, State Electricity Board, Power Line Construction Contractors & Export Customers.
Ceralin Bends
Ceralin Bends of different specifications as required by the customers. NTPC Limited and other Power Generation companies.
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POWER DISTRIBUTION PLAN
D.G. Supply Slip House
Total 4 No. Of 5 Ton Ball Mill/ In Place of one 5 Ton Ball Mill, any 2 Ton Ball Mill, Two Nos. All Filters Press and all other Accessories Compressed Air for B.M. discharge
Manufacturing One Pug Mill Two A.J.M. Machine
Finishing & Tunnel Dryer (TD) Total Process
Glaze Generally up to 10 PM. In case it is require compressed air supply with one compressor
O.T.K & Shuttle Normal Operation for 24 hours
Assembly & Testing (A&T) Total Operation (Exclusion- chilling unit of TCT)
Ceralin Spray Drier One Press 70T/250T HTK Normal Operation Ball Mill operation normal
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CALIBRATION LAB
The Calibration lab is used to calibrate different instruments used in the plants. Firstly the slave instruments are calibrated from the standard instruments and then they are used for the calibration of instrument used in plants time to time.
The instruments used in calibration lab are:-
Name of the Instruments
Vernier Caliper Depth Caliper STD Pressure gauge(40KG/cm2) STD Pressure gauge (250 KG/cm2) STD Pressure gauge (700KG/cm2) STD Vacuum gauge (760KG/cm2) Digital multi-meter (750 Volt) Stop Watch Thermocouple (R type) Thermocouple (K type) Thermocouple (B type) Mer. Thermometer Slip gauge
There are other instruments also like IC Tester which are used to test the functioning of IC.
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CERAMIC LAB In Ceramic lab different tests are done on slip and the bar prepared from the plant to check the different contents of slip and physical properties of the insulator. Generally insulators are made from feldspar, Quartz, Clay etc. So the iron is injurious to the insulators. In this lab the physical & chemical testing are done to determine:
Physical
1. Partial size 2. Thermal Expansion 3. Residue 4. Sp. Gravity 5. Viscosity 6. pH
Chemical
1. Determination of SiO2 2. Determination of Al2O3 3. Determination of Fe2O3 4. Determination of CaO 5. Determination of MgO 6. Determination of K2O 7. Determination of Na2O
Different processed like Spectrophotometry, Flame photometry, EDTA testing, Viscometer, Thermocouple etc. are used in this lab.
Everyday slip & different clay are taken from the slip house to determine different combination in them and the moisture content in them. Then the report is prepared and send to the slip house so that they follow the instruction of the report.
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CHAPTER-4 RIVALS OF BHEL
Major Rivals of
BHEL Jai Shree Insulators, Kolkata (West Bengal) Ws Insulators, Kolkata (West Bengal) Modern Insulators, Chennai Iec, Kolkata (WB) Bathinda Ceramics, Punjab Hi-Tech, Khurja (U.P) Power Tech, Khurja (U.P)
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CUSTOMER’S OF BHEL
Major Customer of
BHEL IP Jagdishpur Jagdishpur Insulator plant has some important customer which are state electricity board, government organizations, public sector units and private customer and Indian Railways.
1. State Electricity Boards UPPCL MPSEB GEB PSEB KSEB KPTCL TNEB MSEB
2. Public Sector Units Power Grid NTPC NHPC DVC NLC Government Organization Govt. of Tripura Govt. of J & K Govt. of Mijoram Govt. of Manipur
3. Private Customer Jyoti Structure JSPL (Jindal Steel Power Ltd.) Associated Transrail Structure Ltd. RPG Transmission Ltd. Tata Project
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Ramji Power Construction EMC (Electric Manufacturing Company) KPTL (Kalputra Power Transmission Ltd.) Devang Electricals
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CHAPTER-5 MANUFACTURING OF
INSULATORS a) For the Manufacturing of Insulator
Storage Slip House Jiggering Unit Finishing Unit Glazing Unit Firing Unit Assembly Unit Testing Unit Dispatch Unit
b) For Manufacturing of Ceralins Storage Slip House Spray Drying Unit Pressure Shaping Unit Firing Chamber Fixing Unit Dispatch Unit
Technical Characteristics Rating : 45KN to 210KN EMS
Creapage Distance: 192mm to 380mm
Locking Device : R/W Type in PB/SS
Glaze Color : Brown/Grey
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Application : Transmission Line from 11kV AC & 500 kV and 800 kV HVDC, Substation.
Process Flow Chart of Disc Insulator
Dewatering
Ball Milling
PuggingPugging
Jiggering Finishing
Drying Glazing
Firing Assembly
Testing Product
Packing
Turning Drying
Glazing Firing
Assembly Product
Packing
Disc
Insulator Hollow
Bushing
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Disc Insulator Manufactured at BHEL IP, Jagdishpur
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STORAGE The different raw material for manufacturer of Insulators are stored in the identified bins. The Raw material are:
1. Quartz
2. Feldspar
3. Felcite
4. Dolomite
5. Alumina
6. Cr2O3
7. Fe2O3
8. Sanding Glaze
9. Calcined Chaibasa Clay
10. Manganese dioxide
11. Chrome Ore
12. Calcite
13. TALC
14. Ellur Clay
15. THAN Clay
16. Quartz for brown glaze
17. Bikaner Clay
18. Pyrophyllite
19. Sericite
20. Japan Ball Clay
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Sample of Raw Materials used to make Insulators (as per the climate)
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Complete Flow Process
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
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SLIP HOUSE The Slip House performs the following operations. All these materials are used in different quantities for different type of insultors that are manufactured and demanded by customers.
The Raw Materials required for manufacturing the insulators are:
FIRST CHARGE
Quartz
Feldspar(stone Powder)
Pyrophillite
River Pebbles
Bikaner Clay
Felsites
Alumina
SECOND CHARGE
THAN Clay
ELLURE Clay
BALL Clay
China Clay
Japan Ball Clay(J.B)
Chaibasa Clay
Wherehouse:
The production in BHEL runs 365 days, and it is a continuous process. Here raw materials are tested before manufacturing the insulators so that raw materials obtained from places satisfies their requirements.
Crushing Plant:
Above said materials other than clay are availbal in the stone from. Crushing plant is used to crush these raw materials into powder from and also it is used to powder the rejected ones for recycling.
Operations
1. Wherehouse
2. Crushing Plant
3. Weighing
4. Charging
5. Ball Mill
6. River-pebble Charging
7. Preparation of first charge Body
slip
8. Preparation of second charge
body slip
9. Blunging return slip
10. Vibroscreening-
Separation/Demagnetization
11. Slip Agitating
12. Preparation of cake
13. Filter Pressing-Dewatering
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Weighing: Different raw materials from the storage bins are collected and weighed aording to the percentage composition given by the E&D and according to the ball mill capacity to be charged. Weighing should be rounded to the nearest multiple of least count. Then the weighing card is attached the lot. A sample data for preparation of superposition body slip in a 5 Ton ball mill for the first charge are as follow:
Charging: It is a preproduction section, before the actual production starts the raw materials have to undergo a certain specifc process. In the slip house the raw materials are got from the material management department. These raw materials are mixed into certain composition according to customer need then these are fed to ball mills.
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Ball Mill Above said materials other than clay are availbal in the stone form. Crushing plant is used to crush these raw material into powder from and also it is used to powder the rejected ones for recycling. The raw material are required to be mixed in different composition. Therefore weighment of raw material is done. Weihted raw materials including clay are mixed with sufficient water ie. 50% of raw materials and 50% water and grinding in the ball mills for duration of (17+3) hours; it is a continuous process round the clock. In the first phase of charging feldsper and quartz is mixed with water for 17 hours, after that clay is mixed for next 3hours. The materials obtained in the ball milling process are called slip or ceramic slurry.
Ball Mill mixing the Raw Materials
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Sanding Glaze Stirage Tank Brown Glaze Storage Tank
River-Pebble Charging: For intial charging of river pebble in the ball mill after rolling large, medium and small pebbles are collected as per standared samples and weighted as per specifications number PPSL:0100 R-2 and pebbles are charged as per the quantity specified. The material are loaded per composition into “BALLMILLS”.In BallMills river-pebbles are put as grinding-media. When ball mills is operated the grinding media and raw materail produced the file paste called ‘Slip’. The ceramic slurry got from the ball mill is fed to the vibrator screens to check for the correct accumulation throughout the materials and also to remove solid particles. Then the materials will be having too less impurities and then goes for filter press to extract water by presing that ceramic body with high pressure. This slip is the input for the ‘filter-press’ to produce cake. This cake is output of slip-house and serve as input for manufacturing jiggering.
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Preparation of first charge: Weighed quantity of 1st charged raw material is charged in to the ball mill by attaching a cone to its hole from the charging hole on the plateform. The pebbles are cleaned with water before charging and then specified quanity of water is charged into the ball mill. Generally charging takes 1-2 hrs. and ball mill runs 14-17hrs.
Preparation of 2nd Charge: Weighed qaulity of 2nd charge is charged in to the ball mill with required quantity of water after preparation of first charge body slip and the ball mill is run for specified time. Then the slip is discharged into the mixing tank and is agitated continuously.
Mixing Storage Tank
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Blunging return Slip: Scrap and water returned by the process in change into the bluger in specified proportion to get required sp. Gravity of the slip. Then it is blunged to achieved homogeneous slip.
Vibroscreening-Seperation/ Demagnetization: The slurry is transffed to the tank form the ball mill to remove the unwanted materials like threads of plastic bag in which the raw materials are stored, wooden piece through vibration and electromagnetic separation. This tank is called discharge tank.
Slip Agitating: After screening the ceramic slurry is transferred to another specifically built bank called top tanks. From this it passed through two vibratory screens which will be rotating continuously to avoid accumulation of raw materials at the bottom and after on top. Then the mixture is fed to Ferro Filter for removing the iron particles. Finaly the fresh Slip is collected in the fresh tank or storage tank.
PREPARATION OF CAKE
Preparation of Cake The slip from the intital tank is pumped into the press using plunger pump then adequate pressure is applied to turn it into a cake, Here the Slip House work is complete.
Filter Pressing: It is dewatering process. In this process 80% of the water is removed from the slip so as to convert the slip into cake from using nylon clothes. In this processs high pressure is applied by compressing them from both side.
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Cake Preparation and Filter Press
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PUGGING
It is a de-airing operation under vaccum. The cakes are filled into pug mills to remove air bubbles present in cakes. In the pug mill homogeneous mixing of cakes takes place, The product which come out after pugging process is called as blanks.
Blanks are extruded from
the pug mills in the
cylindrical form of different
sizes for different types of
insulators. In this process the
moisture content is reduces
up to 22%. Cylindrical blanks
are shaped conically by pre
shaping machine to
facilitate Proper
compaction during forming
process.
Pugging Air Moisture removal
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Blank formation
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JIGGERING
Formation of
Disc Insulator The input for Jiggering station is cake produed by slip-house. The cake are fed into ‘pug-mill’, which under vaccum homogeneous cake in cylinder form, which is cut automatically in required length (as per product), called pugs. These pugs are fed into Jiggering machines, which at first go impart initial shape of insulator shells. The secondary die or final die gives the final shape shells. These green stage shells are dried in CD (Chain-dryer). After drying these shells are taken out of modes and send for finishing.
Pre-shaping blanks are placed into modules which inner side has lining of plaster of paris and shaped on Automatic Jiggering Machine. To avoid sticking between The die and the mould, a mixture of Kerosene oil and Coconut oil is used as Lubricant.
Aluminium Bronze Dies machined and carefully profile finished are used to Shape the insulators. Profile shaped by the Die will not be disturbed further. Insulators are ensured for defects free. Mould will have Aluminium outer Casing for strength and lining of Plaster of Paris- porous material with water absorbing property which facilitates to separate the insulators some times after forming Jiggering.
from BLANK shaping by Primary Die
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DRYING SECTION Insulator after forming are dried in Chain Dryer at 30 to 35°Ϲ for about 2-3 hrs. to facilitate seperation of Insulator from the mould easily. The different drying steps are as follow:
1. Chain Dryer: These dries are used for drying the disc insulators. After this process the insulators will be having less than 15% moisture.
2. Blank Dryer: For hollow insulator and solid core insulator the blanks produced by pug mills are directly fed to these blank driers. For making the hollow insulators and solid core insulators the hardness of blank is much necessary. Therefore blank are dried to see that the moisture content is less than 15%.
3. Mould Releasing of disc Insulators: Insulators are seperated from moulds over Aluminium Ring which supports Green Insulator to helps in handling the insulators at further stages. Insulators are loaded gently to the racks and moved to humidity controlled storage chambers to attain leather hard condition (stored for 10 to 12 hrs at ~ 60% humidity).
4. Oil Inspection: After the disc insulators are dried from chain dryer, they will go for finishing operation. Those processess give a perfect shape for the product and then the visual and oil inspection is carried out for the quality of the product.
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FINISHING SECTION
First the tool and smoothing plates are checked. Before finishing, the article should be checked and defective ones should be discarded. Then the article is placed on the rotating wheel and adequate layer of mass is removed without affecting die formation. Finally smoothening plate is used over entire finished portion to achieve smooth surface finish. The rotating wheel should be at rest while placing and lifting the article. Ambient hummidity is maintained in the finished area by special water sprayers in order to control specifed finishing hardness of the article. The the articles are placed on tunnel drier is maintained as per process specification No. PPS:0202 R-1. The racks are pushed into drier at one end and released at the other end. Necessary corrective action is taken in case the moisture exceeds specified limits.
Finshing of disc insulators on lathe machine
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Insepction- Segregation of Defective Insulators:
Insulators are inspected for different defects. Originated due to stresses induced during forming, mould releasing and handling, based on the position helps in analysis and initiating corrective steps at previous steps.
Defects in Insulators: a) EHM- Mistakes takes due HAND MISTAKING by worker. This can take
palce due to carelessness. b) EFT- It is finishing defect. It can take place shaping process. c) PH- Pin home defect due to poor handling. d) RT- Ring touch defect due to poor handling. e) EMT- Manufacturing defect.
Tunnel Dryers (T.D): The disc insulator after inspection goes into Tunnel dryers for further drying. There are two tunnel dryers, each dryers has 5 zones of tempretures.
Zone Tempreture Range
Zone1 33-47°Ϲ Zone2 48-62°Ϲ Zone3 Minimum 70°Ϲ Zone4 85-103°Ϲ (Heating Zone) Zone5 Minimum 65°Ϲ
In this process moisture is removed through steam, After the drying each product will have less than 1% moisture in it. This model of drying is called drying chamber. Model drying chamber for Hollow Insulators
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Tunnel Dryer
GLAZING UNIT
After the all type of insulators goes for glazing is a process to give the required color to the insulators like red, brown, black and white. Glazing is done to give a coating of 0.3mm to 0.5mm of thickness. Glazing resullts in improved mechanical and electrical stability charterstics.
Good Insulators are glazed in Automatic glazing machine (AGM), Specified specific gravity, viscosity and thickness are maintained to enhance the glaze impact on the insulators.
Sanding is done on pin portion and head portion of glazed insulators to facilitate better grip while cementing the metal parts and improves Mechanical charterstics of the insulators.
Stamping identification made on the insulators based on the customer requirement and standards.
In Glazing Unit there are different operations are exist:
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1. CMC Solution Preparation: Required quantity of water is taken in bucket and then weighted quantity of CMC powder is added slowly to water with continuous stirring. The concentration of CMC solution should be as per specification no. PPS:0203 R-0. The solution should be free from modules.
2. Sanding Glaze Operation: Measured quantity of sanding glaze is mixed with CMC solution and the mix agitated for 30min.
3. Brown Glaze Preparation: Brwon glaze from slip house is mixed with CMC solution as per process specification no PPS-0203 R-0 for specifiaction. The galze is agitated for 30min before se.
4. Glazing Operation The visually inspected articles are loaded on the conveyor bell and article is again inspected for chipping, sharp edges etc. Such defects are removed by rubbing with sharp tool and steel wool. Suficient compressed air jet is applied to the article for removal of dust from the surface. Glaze is applied on the ‘g’ portion of the article with the help of brush of specified thickness. Then the article on loaded on glazing machine’s spindle. The water spray nozel is adjusted for proper spraying. The glazing nozel are also adjusted in such a way that the glaze is poor on the entire surface of the article for a specified glaze thickness. The glaze article is removed from the machine spindle and is placed on auxilary turn table. Glaze from ‘a’ portion of the article is removed with the help of shopping machine.
5. Sanding Operation: Sanding glaze is applied on the ‘f’ portion of the article with brush of suitable width and then sanding grog is poured. The article is then turned upside down and then placed another hand wheel. Sanding glaze is now applied on ‘b’ portion of the article along with the sanding grog. Then the articles are placed on the conveyor hangers.
6. Stamping Operation: Stamping solution is prepared by mixing stamping powder with gycerine as per ratio given in process specification no. PPS: 0203 R-0. The solution is stirred till no nodes are left. A clean stamp per rating is used to stamp the glaze articles. The article are placed on the conveyor racks after stamping. At this point the job of glazing is completed.
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Dust collector
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Conveyor and stamping on Shell of Insulators
FIRING UNIT
The firing work is done in the ‘Kiln’. It is a continuous process. When one car is entering the Kiln from the enterence door, one exits out throughout the exit door. The Kiln tempreture and the cycle tim is maintained as per guide lines of E&D for controlling standared and routine rod thermal expansion at 250 and 650°Ϲ by making suitable adujustments of kiln operation parameters. When the wagon is discharged, the articles are unloaded for visual insepction.
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In Shatal Kiln the insulator stores at 1200 deg. For 58hrs.
ASSEMBLY SECTION
The various operations performed during assembly are:
1. Application of Bituminous Paint: Bituminous paint and thinner are mixed in specific ratio as per specification no. PPS:0400 R-0 for applying coating on cap, pin and shell surface which comes in contact with cement mortar. This paint is applied on the pin by dip method and allowed to dry before assembly. Paints is also applied on inside and outside grog portion of the cap by using a spary gun. The coated shells and caps are allowed to dry before assembly.
2. Preparation of Cement Mortar: Cement and quartz are mixed in cement mixer for 5min. Then the required quantity of water is added. Then the flow value of cement mortar is checked. It is slighly less as specified in PPS: 0400 R-0. Then water is again added and mixed for 3-5 min to bring it to reqiured value.
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3. Assembly of Insulators: Cement mortar is poured inside the cap portion as well as shell portion. A suitable cork is place to insert the ball-pin. The pin is placed manually. The shell is assembled in the cap and is pressed manually. The is twisted while pressing to eliminate entrapped air. The assembly quartz is springed arround the pin. The insulator is lifted and placed on the pre-curing chamber without disturbing alignment of the components. Specified tempreture and humidity of curring chamber is ensurred during initial curring. This is called tempreture curring. The tempreture is attained by blowing steam into chamber from the boiler house. Then the insulators are water cured for 24-36hrs. In underground water tunels at specified tempreture. Finally the insulators are air curred for 24 hrs.
Assembled Insulators
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TESTING SECTION
Testing of Insulators of three types namely:
1. Routine Test 2. Acceptance Test 3. Type Test
Hydraulic Testing 220Kg
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a) Routine Test
It consists of three sub-test. They are i) Physical Verification Test:
After manufacturer, the insulators are inspected visually for cracks and any visual phsical defects. The defected ones are discarded.
ii) Routine Mechanical Test: In this test 40 to 50% of rated mechanical load is applied on the insulators. The insulators incapable of bearing this load breakdown and are immediately discarded.
iii) Routine Electrical Test: The insulators are subjected to high voltage discharge (up to 80 KV) for 10 seconds followed by proper frequency voltage discharge (up to 80KV) for 5min. Then the insulators which are punctured re lebeled with red stickers and other with green stickers. In case of faulty insulators the normal blue discharge arc is charged to yellow flame and insulators is immediately removed by stopping the machine.
b) Acceptance Test
Acceptance tests are conducted as per is-731 and iec-575. Acceptance tests are also called performance tests. These consist of 7 tests. They are:
i) Verification of standard dimensions: The dimension of insulators are verified as per IS-731. They should confirm G.T.P. of drawing. Diameter, spacing, creep-age distance also measured. Then eccentricity of insulators is checked by eccentricity testing machine. It needs venire height gauge and dial gauge for its measurements. It erasures pin to cap spacing with venire gauge which should be according to specification.
ii) Temperature cycle test(TCT): This test is conducted to check the thermal stability of insulators. The entire trolley of insulators is dipped in hot bath for 15 minutes followed by dipping in cold bath for 15 minutes. This cycle is repeated three times. The difference in temperature between hot bath and cold bath should be
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higher than 70°Ϲ. Usually the temperature of hot bath is maintained at 85-90 °Ϲ with the help of water heaters. The temperature of cold bath is maintained at 15-20 °Ϲ with the help of water chillers.
iii) Mechanical Performance Test (MPT): This test is conducted as per IEC-575 in thermo-mechanical chambers. In this test 60% of rated mechanical load which is tensile is applied to string of insulators. The load is 4-6 tons. The load is applied for 24 hrs. Hence it is called 24 hrs. Mechanical performance test. This test is done by thermo mechanical performance testing machine.
iv) Electro –Mechanical test: For electrical test 50-60% of rated voltage at power frequency is applied to the insulators. For mechanical test Universal Testing Machine (UTM) is used where 60 Ton tensile mechanical load is applied to the insulators to measure mechanical strength and breaking load of metal parts. Breaking load must be less than rated value.
Electrical testing 32000Volt
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v) Puncture Test:
This test is conducted to verify or note the voltage at which puncture of insulators occur. This is done in particular tank which contains transformer oil. First the insulator is dipped in the oil and then high voltage (AC) is applied to the insulators till puncture occurs and this voltage is noted. Puncture voltage should not be less than the specified voltage.
vi) Porosity Test: The non-porous property of insulators is checked by porosity test. For this purpose a solution of methyl spirit and a dye (1%) is prepared. Broken pieces of insulators are dropped in the solution and then pressure is applied by the compressors to the insulator loaded chamber for some hrs. Then broken samples are taken out and again broken to check porosity. Pressure in the chamber should not be less than 153 kg/sq. cm.
vii) Galvanizing Test: This test ensures proper coating of zinc on metal parts of insulators to avoid corrosion. It consists of 2 tests: one for mass of zinc on metal parts and other for uniformity of coating. Mass of zinc coating on the cap should not be less than 610 gm/sq-m. For this test we need hydrochloric acid. First pin or cap is weighed and then it is dipped in HCL for sometimes. After reaction it is again weighed and the difference in weights give weight of zinc. Then taking standard area of zinc coating mass in gm/sq.-m is calculated. Similarly pin or cap is dipped in copper sulphate solution (of specific gravity 1.186 gm/cc at 18±2 Deg. C) for 1 min. to check uniformity of coating. This procedure is repeated 5 times. Uniform blue color indicates uniformity of coating.
PACKING & DISPATCH
The ceramic lined cones or bends are then dispatched to the respective customers according to the specifications.
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CHAPTER-6 CONCLUSION
In the age high deficiency of energy we have to use the electrical energy in best manner. The electrical energy is very comfortable to use in daily life. This is the law nature that more reliable thing have more side effect. If make a small mistake in use of electrical energy, then it will become very dangerous. So we need insulator for the saving of electrical energy as well safety from electrical energy.
The insulator is made of ceramics of ceramics and porcelain. In BHEL INSULATOR PLANT Jagdishpur disc insulator, hollow bushing and ceralin is produced. The insulator disc is unit of string used as string.
The bushing is a hollow insulator, allowing a conductor to pass along its center and connect at both ends to other equipment. Bushing are often made of wet-process fired porcelain, and may be coated with a semi-conducting glaze to assist in equalization the electrical stress along the length of the bushing.
Ceralin is manufactured using Calcined Alumina as a raw material. Spray dried powder is then compacted in Hydraulic Presses to form tiles. These tiles are then fired in a high temperature kilns at around 1560-1600°Ϲ to get required wear resistance characteristics.
REFERENCES
The following content has been taken from the
1. www.bhel.com/home.php 2. www.economictimes.indiatimes.com/bharat-heavy-electricals-
ltd/infocompanyhistory/companyid-11831.cms 3. https://en.wikipedia.org/wiki/Bharat_Heavy_Electricals 4. BHEL Annual Report 2013-14 (English) from www.bhel.com
