MANUFACTURING OF INSULATORS AT BHEL(IP) Jagdishpur plant
DATED :14.6.12 – 15.67.12UNDER GUIDENCE: PRESENTED BY:MR. M.K.SINGH AMBESH SINGH(QUALITY DEPT.) ME 4th YEARBHEL(IP) R.R.S.I.M.T.JAGDISHPUR AMETHIA PRESENTATIONON“PRODUCTION PROCESS IN MAKING INSULATOR”ATBHARAT HEAVY ELECTICAL LIMITED(INSULATOR PLANT)JAGDISHPUR(U.P.)
Bharat Heavy Electricals Limited is the largest Engineering and ManufacturingEnterprise of its kind in India established in 1964 . It ranks amongst the leadingmanufacturers of power plant equipment in the world. It is also one of theNAVRATNA industries.JAGDISHPUR UNIT OF BHEL IS DIVIDED IN TWO MAIN UNITS:BHEL (CSU)BHEL (IP)BHEL (IP) IS LEADING MANUFACTURER OF HIGH TENSION INSULATORSAND DISTRIBUTION INSULATORS.THE PLANT IS EQUIPPED WITH HIGHLYSOPHISTICATED PLANT AND MACHINARY.MAJOR CONSUMERS OF BHEL IP INSULATORS ARE:NTPCPOWER GRID COOPERATION OF INDIASTATE ELECTRIC BOARDR.P. GOENKA GROUP OF INDUSTRIESEXPORT TO MIDDILE AND EAST AFRICAN COUNTRIES
The insulators are used in over head lines for providing insulation to the powerconductors from ground. They are made from porcelain ,ceramic and toughenedglass .There are three type of insulators used in over headlines:Pin typeSuspended typeStrain type
MANUFACTURING PROCESS OF INSULATORS1. Storage2. Slip house3. Jiggering Unit4. Finishing Unit5. Glazing Unit6. Firing Unit7. Assembly Unit8. Testing Unit9. Dispatching Unit
1)STORAGEThe different raw materials used for manufacturing of insulators are storedin the identified bin. They are :-a) Clayb) Quartzc) Brown glazed) Talke) Feldsparf) Pyrophyliteg) Felciteh) Pebbles
2)SLIP HOUSEa)Weighting:For preparing a body slip in 5 ton ball mill are-Quartz - 1053kgFeldspar - 603kgPyrophylite - 653kgClay - 387kgFelcite - 201kgPebbles - 157kgb )Crushing of raw material in BALL MILLS.
c)Checking slip parameters.d)Demagnetization of slip.e)DEWATERING of charged slip in second ball mill.f)Passing it from Vibroscreen.g)Preparation of cake by passing it into pressure pads by removing excess water .
3)JIGGERING UNITThen the cake is passed through plungmills where continuous cylindricalmoulds are released and then they as cut into required length by threadcutters automatically or manually.Then these moulds are shaped into required shape. By automatic jiggeringmachine.
4)FINISHING AND DRYINGAll the articles are checked and defective ones are discarded.Then they are placed into rotating wheel and adequate layer of mass isremoved without affecting articles.Then they are tunnel drive cars and the cars led into them in dryingchamber , where steam pressure provide heating with in specific limits.
6)FIRING UNITThe firing operation is done in the kiln where continuously one car isentering from entrance door and one exit out through exit door. Bypassing though it there standard is tested.7)ASSEMBLY SECTIONApplication of paintPreparing of cement mortarFixing of caps , pin and holdersAssembling of insulators
8)TESTING UNITa) ROUTINE TEST Physical verification test Routine mechanical test Routine electrical testb) ACCEPTANCE TEST Verification of dimension Temperature cycle test Mechanical performance test Porosity test
9)DISPACHING UNITT hen the ceramic insulators then dispatched to respective customers.