1. Bharat Heavy Electricals Ltd.
AN GOVERNMENT OF INDIA UNDERTAKEN
INSULATOR PLANT, JAGDISHPUR (AMETHI) U.P.
2. Prepared by:
Bhupendra Kumar Shukla
Reg. No: 11205580
Roll No: RM1204B43
School of Mechanical Engineering
Lovely Professional University, Jalandhar
3. 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
4. Trophy conferring Maharatna status on BHEL
from Hon’ble President of India in recognition
of company’s consistent high performance
Sh. R. Krishnan, Director (HR) BHEL was
conferred NIT-Trichy’s Distinguished Alumnus
Award by the former President of India,
Dr. A.P.J. Abdul Kalam as part of Golden
Jubilee celebrations of the Institute
5. 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 INSULATORS
a) 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 Insulator
Code 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
6. 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
7. MANUFACTURING OF INSULATORS
1. For Manufacturing of Disc Insulator
Storage
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
8. Flow Process of Insulators
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
9.
10. 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
12. 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
13. Pugging Machine
Under this the Blanks are
formed though the Pugging
machine, the remaining 22%
moisture has been removed.
D= 80mm L= 220mm
PUGG MILL
14. Jiggering Plant
Under this the formation of Insulator has been done
The two dies Primary and Secondary dies
15. Model Drying Chamber for Hollow Bushing Dust Collector, for the Insulators
Glazing Machine for Painting
GLAZING PLANT
16. Stamping on Cell Shatal Kiln Shatal Kiln at 1200 deg-cen
STAMPING & FIRING UNIT
17. Hydraulic Test Electrical Testing, 156000Volt
Mechanical Testing 100KN Tensile
Force
ASSEMBLY & TESTING
