BHEL AT JAGDISHPUR

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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.

6. 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
43337
49510 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.

26. 23 | P a g e
- 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.

27. 24 | P a g e
 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

28. 25 | P a g e
 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

29. 26 | P a g e
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.

30. 27 | P a g e
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

31. 28 | P a g e
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.

32. 29 | P a g e
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.

33. 30 | P a g e
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)

34. 31 | P a g e
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

35. 32 | P a g e
 Ramji Power Construction
 EMC (Electric Manufacturing Company)
 KPTL (Kalputra Power Transmission Ltd.)
 Devang Electricals

36. 33 | P a g e
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

37. 34 | P a g e
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

38. 35 | P a g e
Disc Insulator Manufactured at BHEL IP, Jagdishpur

39. 36 | P a g e
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

40. 37 | P a g e
Sample of Raw Materials used to make Insulators (as per the climate)

41. 38 | P a g e
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

42. 39 | P a g e
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

43. 40 | P a g e
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.

44. 41 | P a g e
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

45. 42 | P a g e
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.

46. 43 | P a g e
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

47. 44 | P a g e
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.

48. 45 | P a g e
Cake Preparation and Filter Press

49. 46 | P a g e
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

50. 47 | P a g e
Blank formation

51. 48 | P a g e
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

52. 49 | P a g e
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.

53. 50 | P a g e
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

54. 51 | P a g e
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

55. 52 | P a g e
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:

56. 53 | P a g e
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.

57. 54 | P a g e
Dust collector

58. 55 | P a g e
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.

59. 56 | P a g e
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.

60. 57 | P a g e
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