This document provides information about Amar Prem's summer training completed at Bharat Heavy Electricals Limited (Insulator Plant) in Jagdishpur, Uttar Pradesh from June 1st to June 30th, 2016. It includes a certificate signed by his supervisor, Gaurav Pandey, certifying that Amar Prem was cooperative, sincere, and hard working during his training. The document also includes an acknowledgement from Amar Prem thanking BHEL staff for their guidance. Finally, it outlines the various manufacturing processes at the BHEL insulator plant, including sections on insulators, the power distribution plan, calibration lab, ceramic lab, boiler, and detailed descriptions of manufacturing insulators and ceralins.

1. 1
Submitted in the requirement partial fulfillment
for the award of certificate of summer training
AT
Bharat Heavy Electricals Limited
INSULATOR PLANT
Jagdishpur (UP)
Under the supervision of :- Submitted by :-
Gaurav Pandey Amar Prem
Engineer (Manufacturing/Production) B.Tech (P.I.E)
Bharat Heavy Electricals Limited Motilal Nehru National
Jagdishpur, Sultanpur (UP) Institute of Technology
Allahabad
Uttar Pradesh

2. 2
This to certify that Amar Prem student of B.Tech in
Production & Industrial Engineering (4th
sem) from
Motilal Nehru National Institute of Technology has
completed his summer training in Bharat Heavy
Electricals Limited (Insulator Plant) Jagdishpur from
01.06.2016 to 30.06.2016.
During this period I found his to be very co-operative,
sincere & hard Working.
I Wish his good luck and success for all his future
assignments.
( Gaurav Pandey )
Engineer/Production
Bharat Heavy Electricals Limited
Jagdishpur, Sultanpur
Uttar Pradesh

3. 3
ACKNOWLEDGEMENT
I am very thankfull to all concerning officers and
staff of BHEL, I.P. Jagdishpur for their valuable
guidance and advice without which I could not have
completed my summer training.
Amar Prem
B.Tech (P.I.E)
Motilal Nehru National Institute of Technology
Allahabad
Uttar Pradesh

4. 4
CONTENTS
1. An Introduction to BHEL IP Jagdishpur
2. Insulators
3. Power Distribution Plan
4. Calibration Lab
5. Ceramic Lab
6. Boiler
7. Manufacturing Process
8. Manufacturing Of Insulators
a) Storage
b) Slip House
c) Jiggering Unit
d) Finishing Unit
e) Glazing Unit
f) Firing unit
g) Assembly Section
h) Testing Section
i) Despatch Section
9. Testing Of Insulators
a) Routine Test
b) Acceptance Test
c) Type Test
10.Manufacture of Ceralin
11.Evaluation Criteria & its Impact
12.Environmental Policy Of BHEL
13.Conclusion

5. 5
1)BHEL Jagdishpur – An Introduction
Jagdishpur unit of BHEL is the leading manufacturer of high tension porcelain
insulators and distribution insulators like Bobbin, Shakle, Guy/Stay/Strain, Pin,
Cap and pin type Post insulators in the country. The plant is equipped with highly
sophisticated plant and machinery. This division also offers wear resistance high
alumina ceramic lining materials for power, steel, cement and mining industries
as well as a wide range of industrial ceramics.
The product portfolio can be divided into three categories:-
 LT type insulators
 Disk type insulators
 Ceralins
(a) LT type insulators
These can be divided into four categories. They are:-
 Pin type ( 10 KN. With creepage distance of 230/280/320 mm)
 Guy/Stay/Strain type( 53/89/110 KN with creepage distance of
42/52/65/72 mm)
 Shakle (11.5/15/16 KN. With creepage distance of 63/70/75 mm)
 Post type.
(b) Disk type insulators
According to codes, they are divided into:-
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. 6
(C) Ceraline:
Under ceramic line products or Ceralins it manufactures blends, cones,
ventury vanes, O’Collars, multiple discharge valves, multiple outlets, fuel inlet
elbows and other applications. Flyash tiles are also produced as per customer
requirements.
Major Customers:
Major customers of BHEL IP Jagdishpur are
1) NTPC
2) Power Grid Corporation of India Ltd.
3) State Electricity Boards
4) R.P. Goenka group of industries
5) Export to Middle East and African countries
The total plant capacity is 6000 CMT (Excluding the weight of metal parts)

7. 7
INSULATORS
The insulators for overhead lines provide insulation to the power
conductors from ground. The insulators are connected to cross arms of the
supporting structures of the power conductors and the power conductors pass
through a clamp of the insulators. The insulators are mainly made of either
glazed porcelain or toughened glass. The materials used for porcelain are
silica 20%, feldspar 30% and clay 50%. The porcelain should be ivory white,
sound and free from defects. It should be vitrified because the presence of air
lowers the dielectric strength of porcelain. It is therefore desirable that the
porcelain to be used for insulators should be air free and impervious to
entrance of liquids and gases .The dielectric strength of porcelain should be
15 to 17 KV for every 1/10th
inch of thickness. Normally it is difficult to
manufacture homogeneous porcelain, and therefore for a particular operating
voltage, two, three or more piece-construction is adopted in which each piece
is glazed separately and then they are cemented together. Porcelain is
mechanically strong, less affected by temperature and has minimum leakage
problem.
Toughened glass is also sometimes used for insulators because it has
higher dielectric strength (35 KV for1/10th
inch thicknesses) which makes it
possible for single piece construction, whatever be the operating voltage. As
glass is transparent, the flaws like trapping of air can be detected. It has
lowered co-efficient of thermal expansion. It has a disadvantage that moisture
condenses very easily on its surface, limiting its use to about 33KV.
It is not desirable to allow porcelain and metal pieces to come together.
So cement is used between them. It is seen that cement does not cause
fracture by expansion or contraction.
There are three types of insulators used for overhead lines. They are:-
 Pin type
 Suspension type
 Strain type

8. 8
i) Pin type
Pin type insulators are normally used up to 33kv. In any case it is not
desirable to use them beyond 50 V as the cost of insulation becomes too
high.
ii)Suspension type
Suspension type insulators, in addition to being economical as
compared to pin type for voltage more than 33KV have the following further
advantages:
1) Each insulator is designed for 11KV and hence for any operating voltage a
string of insulators can be used.
2) In case of failure of one of the units of string, only that particular unit
needs replacement rather the whole string.
3) The operating voltage of existing transmission can be increased by adding
suitable number of disks.
iii) Strain Type
Strain insulators are placed in horizontal plane rather the vertical plane
as is done in case of suspension. These are used to take the tension of
conductors at line terminals, angle towers, road crossings and junction of
overhead lines with cables. For low voltages of order 11KV, the shackle
insulators are used.

9. 9
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 Filter Press and all other Accessories.
 Compressed Air for B.M. discharge
Manufacturing
 Three Pug Mill
 Three Automatic Jiggering Machine
Finishing & TD
 Total Process
Glaze
 Generally upto 10 PM. In case it is require compressed air supply with one
compressor
TK & Shuttle
 Normal Operation for 24 hours.
A & T
 Total Operation (Exclusion –Chilling unit of TCT)
Ceralin
 Spray Drier
 One Press 70 T / 250 T
 HTK Normal Operation
 Ball Mill operation normal
Services
 Pump house:- Only one pump at any point of time.
 Siverage pump:- normal operation (It possible use 15 HP motor only in night)
 Boiler:- Normal operation
 Compressor :- 1 Nos. in night shift ( on requirement )

10. 10
CALIBRATION LAB
The calibration lab is used to calibrate different instruments used in the
plant. Firstly the slave instruments are calibrated from the standard
instruments and then they are used for the calibration of instruments used in
plants time to time.
The instruments used in calibration lab are:-
Name Of Instruments
1. Vernier Caliper
2. Depth Caliper
3. STD Pressure gauge(40 KG/cm2)
4. STD Pressure gauge(250 KG/cm2)
5. STD Pressure gauge(700 KG/cm2)
6. STD Vacuum Gauge(760 MMHG)
7. Digital multimeter(750 Volt)
8. Stop watch
9. Thermocouple(R type)
10. Thermocouple(K type)
11. Thermocouple(B type)
12. Mer. Thermometer
13. Slip gauge
There are other instruments also like IC TESTER which are used to test the
functioning of IC.

11. 11
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. Particle 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 processes like Spectrophotometry, Flame photometry, EDTA
testing, Viscometer, thermocouple etc are used in this lab.
Every day slip & different clay are taken from the slip house to determine
different contamination 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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BOILER
1. Evolve Material, Water and Oil balance for individual production operations and utility
functions.
2. Effluents from Ceralin, Boiler blow down and softner plant is let into open land, the
same should be channelised to industrial drain.
3. Most of the water line valves are leaking the same has to be repaired / replaced.
4. Many places water valves are kept in open condition even if not required. Due
diligence should be exercised to avoid unnecessary wastage.
6. At jiggering machines transfer mechanism is not in use but the hydraulic system is
running redundantly in all the three machines.
7. Water level controllers at pump house can be introduced
8. Efficiency monitoring should be carried out for Boiler, Compressors and DGs
9. Lub-oil consumption of DG should be monitored and recorded.
10. Steam, condensate and compressed air leakages in the distribution system to be
avoided and constantly monitored.
11. Monthly stack emission to be monitored and reported to UPSPCB for all the stack.
16. Waste oil being hazardous - authorisation to be obtained for storage, handling and
disposal of the same. Proper storage facility to be made and company wide oil balance to
be drawn.
Manufacturing Process
The various manufacturing units at BHEL IP Jagdishpur are as follows:
a) For manufacturing insulators
i. Storage
ii. Slip House
iii. Jiggering Unit
iv. Finishing Unit
v. Glazing Unit
vi. Firing Unit
vii. Assembly Unit
viii. Testing Unit
ix. Dispatch Unit
b) For manufacturing of ceralins
i. Storage
ii. Slip House

13. 13
iii. Spray Drying unit
iv. Pressure Shaping Unit
v. Firing Chamber
vi. Fixing Unit
vii. Dispatch Unit
MANUFACTURING OF INSULATORS
I) STORAGE
The different raw materials for manufacture of insulators are stored in
the identified bins. The raw materials are:-
1) Calcined Chaibasa clay
2) Dolomite
3) Manganese dioxide
4) Chrome ore
5) Calcite
6) Talc
7) Ellur Clay
8) Than Clay
9) Quartz for brown glaze
10)Quartz
11)Feldspar
12)Bikaner clay
13)Pyrophyllite
14)Felcite
15)Sericite
16)Japan ball Clay
II) SLIP HOUSE
Slip house performs the following operations:
1. Weighing
Different raw materials from the storage bins are collected and weighed
according to the percentage composition given by the E&D and according to
the ball mill capacity to be charged. Weighing should be rounded to nearest
multiple of least count. Then the weighing card is attached to the lot.
A sample data for preparation of suspension body slip in a 5 ton ball mill
for the first charge are as follows:

14. 14
2. River-pebble charging:
For initial charging of river pebble in the ball mill after reling, large,
medium and small pebbles are collected as per standard samples and
weighed as per specification No. PPSL: 0100 R-2 and pebbles are charged
as per the quantity specified.
3. Preparation of first charge Bodyslip:
Weighed quantity of first charged raw materials are first charged into
ballmill by attaching a cone to its hole from the charging hole on the platform.
The pebbles are cleaned with water before charging. Then specified quantity
of water is charged into the ball mill. The ballmill is run for the specified time
and initial and final meter reading , time , ballmill number are also noted. Then
a little quantity of first slip is collected for checking slip parameters. Generally
charging takes 1-2 hrs and ballmill runs 14-16 hrs.
4. Preparation of second charge body slip
Weighed quantity of second charge is charged into the ballmill
with required quantity of water after preparation of first charge bodyslip and
the ballmill is run for specified time. After complete grinding the ballmill is
stopped and sample is collected for checking slip parameters. Then the slip is
discharged into mixing tanks and is agitated continuously.
5. Blunging return slip:
Scrap and water returned by the process is charged into the
blunger in specified proportions to get required specific gravity of the slip.
Then it is blunged to achieve homogeneous slip. Then the slip is transferred
to return storage tank by passing through Vibroscreen. The timely removal of
foreign materials from the Vibroscreen should be ensured.
6. Preparation of cake:
The filter press cloth should be free from folding and clay sticking
before pressing operation and this must be ensured. The adequate power
Quartz 1053 kg
Feldspar 603 kg
Pyrophylite 653 kg
Bikaner clay 387 kg
Felcite 201 kg
Pebbles 157 kg ( due to the presence of
previously charged pebbles in
the Ball Mill)

15. 15
pag pressure is applied and filter press is closed. The slip from the final tank
is pumped into the press using plunger pump at 10-12 kg /sq. cm pressure to
get cake of specified hardness as per process specification No. PS: 0100 R-
Z. Then power pag pressure is released and cake is removed. Cake hardness
is checked and cake is stored in specified area in stacks. Here the sliphouse
work is completed.
III) JIGGERING UNIT
The cake from the sliphouse is fed into the plungmill. Plungmill makes dough
of the cake and releases it in continuous cylindrical moulds. This continuous
cylinder is cut into the required length by thread cutters. In some plungmills
the cutting process is automatic. Then these moulds are shaped into required
shapes by automatic jiggering machines. In case of pin insulators it is done
manually by cutting machines.
IV) FINISHING UNIT:
First the tools and the smoothing plates are checked. Before finishing,
the article should be checked and 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 humidity
is maintained in the finishing area by special water sprayers in order to control
specified finishing hardness of the article. Then the articles are placed on
tunnel drier cars and the cars are led into temperature drying chambers. The
stream pressure / waste heat is regulated and temperature of each zone of
dryer is maintained as per process specification No. PPS: 0202 R-1. The
racks are pushed into the drier at one end and released at the other end.
Necessary corrective action is taken in case the moisture exceeds specified
limits.
v) GLAZING UNIT
Operations carried out:
1) CMC Solution preparation:
Required quantity of water is taken in a bucket and then weighed
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 Preparations:

16. 16
Measured quantity of sanding glaze is mixed with CMC solution
and the mix is agitated for 30 min.
3) Brown Glaze Preparation:
Brown Glaze from slip house is mixed with CMC solution as per process
specification no. PPS:0203 R-0 for specified concentration. The glaze is
agitated for 30 min before se.
4) Glazing operation:
The visually inspected articles are loaded on the conveyor belt and
article is again inspected for chipping, sharp edges etc. Such defects are
removed by rubbing with sharp tools and steel wool. Sufficient compressed
air jet is applied to the articles 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 articles are loaded on glazing machine’s spindle. The
water spray nozzle is adjusted for proper spraying. The glaze nozzles 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 auxiliary turn table. Glaze from ‘a’ portion of
the article is removed with the help of sponging 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 on the wooden planks with sponge bedding.
Then the article is placed on another hand wheel. Sanding glaze is now
applied on ‘b’ portion of the article along with sanding grog. Then the articles
are placed on the conveyor hangers.
6) Stamping Operation:
Stamping solution is prepared by mixing stamping powder with
glycerin as per ratio given in process specification no. PPS: 0203 R-0. The
solution is stirred till no nodes are left. A clean stamp as per rating is used to
stamp the glaze articles. The articles are placed on the conveyor racks after
stamping. At this point the job of glazing is completed.
vi) FIRING UNIT:
The firing work is done in the kiln. It is a continuous process. When
one car is entering the kiln from the entrance door, one exits out through the
exit door. The kiln temperature and the cycle time is maintained as per guide

17. 17
lines of E&D for controlling standard and routine rod thermal expansion at 250
and 650 deg C by making suitable adjustments of kiln operation parameters.
When the wagon is discharged, the articles are unloaded for visual
inspection.
vii) 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 come in contact with cement mortar. This paint is applied on
the pin by dip method and is allowed to dry before assembly. Paint is also
applied on inside and outside grog portion of the cap by using a spray 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 5 min. then the
required quantity of water is added. Then the flow value of cement mortar is
checked. If it is slightly less as specified in PPS: 0400 R-0 , then water is
again added and mixed for 3-5 min. to bring it to required value.
3. ASSEMBLY OF INSULATORS:
Cement mortar is poured inside the cap portion as well as the shell
portion. A suitable cork is placed to insert the ballpin. The pin is placed
manually. The shell is assembled in the cap and is pressed manually. The
shell is twisted while pressing to eliminate entrapped air. The assembly quartz
is sprinkled around the pin. The insulator is lifted and placed on the pre-curing
chamber without disturbing the alignment of the components.
4. ASSEMBLY OFINSULATORS:
Specified temperature and humidity of curing chamber is ensured during
initial curing. This is called temperature curing. The temperature is attained by
blowing steam into chamber from the boiler house. Then the insulators are
water cured for 24-36 hrs. in underground water tunnels at specified
temperature. Finally the insulators are air cured for 24 hrs.
VIII) TESTING SECTION
The testing section is described in details in a later section

18. 18
IX) DISPATCH SECTION:
The tested insulators are packed in seasoned mango wood
crates with weather proof nature. They are then dispatched to customers
according to work orders.
TESTING OF INSULATORS
Testing of insulators is of three types namely:
1. Routine test
2. Acceptance test
3. Type test.
Routine Test
It consists of three sub tests. They are:
a) Physical verification test:
After manufacture, the insulators are inspected visually for cracks and
any visual physical defects. The defected ones are discarded.
b) 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.
c) 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 80 KV) for
5 min. Then the insulators which are punctured re labeled with red stickers
and others with green stickers. In case of faulty insulators the normal blue
discharge arc is changed to yellow flame and insulator is immediately
removed by stopping the machine.

19. 19
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:
a) Verification of standard dimensions:
The dimension of insulators are verified as per IS-731. They should confirm
G.T.P. of drawing. Diameter, spacing, creepage 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 easures
pin to cap spacing with venire gauge which should be according to
specification.
b) 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 higher than 70 deg C .
Usually the temperature of hot bath is maintained at 85-90 Deg C with the
help of water heaters. The temperature of cold bath is maintained at 15-20
Deg C with the help of water chillers.
c) 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 hr mechanical performance test. This test is done by thermo
mechanical performance testing machine.
d) 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 tonne tensile mechanical load is applied to the

20. 20
insulators to measure mechanical strength and breaking load of metal parts.
Breaking load must be less than rated value.
e) 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.
f) 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.
g) 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 sometime. 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.
TYPE TEST:
Type test are conducted only once for not less than 2 insulators per
batch. Some tests are conducted for both the insulators and some tests are
conducted only once. All these tests should be conducted at specified
atmospheric conditions, and then they must be corrected to 16 tests including
7 acceptance tests. Some of type tests are:
a) Power frequency with standard voltage test
b) Dry flash over voltage test
c) Wet flash over voltage test

21. 21
d) Pollution flash over voltage test
e) Impulse flash over voltage test
f) Sweeping surge test
g) Steep wave front test
Impulse Voltage withstanding test
It is a type test conducted on insulators to check impulse
withstands or flash over voltage. Impulse generator gives impulse for
some time and voltage is noted. Impulse may be lightening or switching.
For lightening impulse rise time is equal to 1.2 micro seconds 30%. Fall
time is equal to 50 microseconds 20%. For switching impulse rise time is
equal to 250 microseconds. Fall time is equal to 1250 microseconds.
MANUFACTURE OF CERALIN
1. STORAGE
Different raw materials are stored in identified bins. The raw materials
are:
1) Alumina
2) Quartz
3) Tale
4) Clay
2. SLIP HOUSE
Weight quantities of raw materials are charged into the ball mill.
Also adequate quantity of water is added. The ball mill is run for specified
time period. A slip is prepared. Then the ball mill is discharged into
storage tanks which have continuous agitation facility.
3. SPRAY DRYING UNIT:

22. 22
The slip is pumped into the spray drying unit and is sprayed to
the hot surface of the drier. The drier is heated by a burner which supplies
heat by burning diesel. Due to this the slip is converted into powder form.
4. PRESSURE SHAPING UNIT
First the building material like PVM is added to the powdered
material. Then the powdered material is pressed into desired shape by
pressing it at high pressure in the specified dies. The required holes are
also punched by punching machines on the slabs.
5. FIRING UNIT
The bricks are placed on the kiln trolleys and are led into the kiln.
The kiln used here is a high temperature kiln (1700 deg c). Then after
firing the bricks are visually inspected for any broken edges and only non
defective ones are supplied to the firing unit.
6. FIRING UNIT
The ceramic tiles are fixed to the inner surface of supplied
cones or bends with the help of cementing materials. At places where very
thin lining is required a silicon adhesive is used in place of cement. In this
case the ceramic tiles are also fixed to the iron body of the bends or cones
by welding iron butts through the hole in the ceramic tiles.
7. DISPATCH UNIT
The ceramic lined cones or bends are then dispatched to the respective
customers according to the specifications.
EVALUATION CRITERIA & ITS IMPACT

23. 23
DEPT :CERALIN PRODUCTION
------------------------------------------------------------------------------------------------------------
ACTIVITY ASPECT IMPACT
1.RAW MATERIAL GENERATION OF AIR POLLUTION,
TRANSPORTATION DUST & SPILLAGE DEPLETION OF
OF RAW MATERIAL NATURAL
FORK LIFT EMISSION RESOURCES
2: .BALL MILLING
2.1. WEIGHMENT GEN. OF DUST, AIR POLLUTION
SPILLAGE OF RM
2.2BALL MILLING GEN. OF DUST & AIR POLLUTION
NOISE
3.FILTER PRESSING SPILLAGE OF WATER DNR
4.CLOTH WASHING WATER WASTAGE DNR & WATER
POLLUTION
5.BALL MILL LINING GEN. OF WASTE WATER
POLLUTION
6.CAKE DRYING
6.1 TRANSPORTATION SPILLAGE OF CAKE AIR POLLUTION
OF GREEN CAKE LAND
CONTAMINATION
7.POWDERING GEN. OF DUST AIR POLLUTION
8.BINDER SPILLAGE OF DNR, AIR POL.
PREPARATION PVA,OIL
9.MIXING GEN. OF DUST AIR POLLUTION
& SPILLAGE & DNR
10.COMPACTION SPILLAGE OF POWDER DNR
11.FIRING SPILLAGE OF HSD OIL, DNR & LAND
LPG, CONTAMINATION
GEN. OF HEAT (SOLID WASTE)
GEN. OF WASTE WATER
GEN. OF WASTE REFRACTORIES

24. 24
12. CERALIN ASSEMBLY
1. TRANSPORTATION GEN. OF CEMENT DUST DNR & AIR
OF CEMENT BAGS GEN. OF CEMENT BAGS POLLUTION
(STORES TO SHOP) LAND
CONTAMINATION
2. CEMENT MIXING SPILLAGE OF MIX, DNR,LAND
WATER CONTAMINATION
3. TILE CUTTING GEN. OF NOISE NOISE POL.
4. TILE GRINDING GEN. OF DUST AIR POLLUTION
5. WELDING GEN. OF FUMES, AIR POLLUTION
HEAT
6. GAS CUTTING GEN, OF FUMES AIR POLLUTION
7. PAINTING SPILLAGE OF PAINTS AIR POLLUTION
& EMISSION OF
VAPOUR
8. HANDLING
CRANE GEN. OF NOISE NOISE POLLUTION
9. APPLYING GEN, OF VAPOURS AIR POLLUTION
SILICONE ADHESIVE
10. TILE PACKING GEN. OF WASTED DNR & LAND
PAPER,PLASTIC & CONTAMINATION
WOOD
11. REJECTED TILES GEN. OF SOLID LAND CONTAMINATION
STORAGE WASTE
Environmental Policy of BHEL

25. 25
Environmental manual
The company has documented an Environmental Management System manual
laying down procedures and instructions to ensure adequate environmental care
throughout its operations and activities. The EMS Manual covers all the core
elements of the standard.
Environmental policy
Top Management has defined, documented, implemented and maintained an
environmental policy. The Policy is signed by the General Manager and is
appropriate to the nature , scale and environmental impacts of the company’s
activities. The policy sets a framework for setting and reviewing the environmental
objectives and targets. A system has also been established to ensure that the
policy is communicated to all employees and is available to public and all
interested parties. The Policy is displayed at prominent places, distributed to all
employees through cards in Kannada, Hindi and English Languages. It is available
to the public, contractors, suppliers and other interested parties. The awareness of
the Policy amongst all concerned in the company and residential complex was
found to be generally high.
Objectives and targets
The management has set up objectives at organisational and Departmental levels.
These are consistent with the policy based on significant aspects and legal
requirements. For each objective the departmental targets have been set giving
consideration to the technological options available, operational requirements and
views of the interested parties. The objectives / targets are reviewed on regular
basis at least once in six months.
Some of the salient objectives having defined targets are as under :
1. To avoid generation of dust in the batch weighment area of Slip House.
2. Prevention of long term land pollution on account of oil and grease leakage
during ball mill operation
3. Prevention of water pollution due to oil leakage during membrane pump
operation
4. Utilisation of polluted water from filter press operation for miscellaneous
production uses.
5. Prevention of water pollution due to oil leakage during the filter press operation
6. To reduce rejection of fired insulators for the year 2000-01
7. Reduce the dust level in dry finishing areas by installation of dust collection /
extraction equipment.
8. Recycling of cooling water in Netzsch Pug Mill & Jiggering machines and Ceralin
– Bickley kiln sand seal.
9. Replace asbestos material with non-asbestos material for various process
equipment use.
10. To store hazardous waste at scrap yard scientifically by providing separate
storage bins impervious floor and covered roof.
11. To collect the spills and leaks of electrolyte of batteries using stainless steel tray
and reuse of collected electrolyte for batteries maintenance
12. To collect the oil leaking from lube oil filters in MS tray
13. Providing storage and handling facilities for waste oil
14. To eliminate the pollution caused by coal hearth during smithy operation by
changing over to LPG heating.
15. To eliminate air pollution caused by diesel forklifts by changing over to LPG.