this slide contain material regarding the manufacturing process of insulators in the bhel-ip plant jagdishpur up

1. DATED :14.6.12 – 15.67.12
UNDER GUIDENCE: PRESENTED BY:
MR. M.K.SINGH AMBESH SINGH
(QUALITY DEPT.) ME 4th YEAR
BHEL(IP) R.R.S.I.M.T.
JAGDISHPUR AMETHI
A PRESENTATION
ON
“PRODUCTION PROCESS IN MAKING INSULATOR”
AT
BHARAT HEAVY ELECTICAL LIMITED(INSULATOR PLANT)
JAGDISHPUR(U.P.)

2. Bharat Heavy Electricals Limited is the largest Engineering and Manufacturing
Enterprise of its kind in India established in 1964 . It ranks amongst the leading
manufacturers of power plant equipment in the world. It is also one of the
NAVRATNA industries.
JAGDISHPUR UNIT OF BHEL IS DIVIDED IN TWO MAIN UNITS:
BHEL (CSU)
BHEL (IP)
BHEL (IP) IS LEADING MANUFACTURER OF HIGH TENSION INSULATORS
AND DISTRIBUTION INSULATORS.THE PLANT IS EQUIPPED WITH HIGHLY
SOPHISTICATED PLANT AND MACHINARY.
MAJOR CONSUMERS OF BHEL IP INSULATORS ARE:
NTPC
POWER GRID COOPERATION OF INDIA
STATE ELECTRIC BOARD
R.P. GOENKA GROUP OF INDUSTRIES
EXPORT TO MIDDILE AND EAST AFRICAN COUNTRIES

3. The insulators are used in over head lines for providing insulation to the power
conductors from ground. They are made from porcelain ,ceramic and toughened
glass .
There are three type of insulators used in over headlines:
Pin type
Suspended type
Strain type

4. 1)Pin type 2) Strain type 3) Suspended type

5. MANUFACTURING PROCESS OF INSULATORS
1. Storage
2. Slip house
3. Jiggering Unit
4. Finishing Unit
5. Glazing Unit
6. Firing Unit
7. Assembly Unit
8. Testing Unit
9. Dispatching Unit

6. 1)STORAGE
The different raw materials used for manufacturing of insulators are stored
in the identified bin. They are :-
a) Clay
b) Quartz
c) Brown glaze
d) Talk
e) Feldspar
f) Pyrophylite
g) Felcite
h) Pebbles

7. 2)SLIP HOUSE
a)Weighting:
For preparing a body slip in 5 ton ball mill are-
Quartz - 1053kg
Feldspar - 603kg
Pyrophylite - 653kg
Clay - 387kg
Felcite - 201kg
Pebbles - 157kg
b )Crushing of raw material in BALL MILLS.

8. c)Checking slip parameters.
d)Demagnetization of slip.
e)DEWATERING of charged slip in second ball mill.
f)Passing it from Vibroscreen.
g)Preparation of cake by passing it into pressure pads by removing excess water .

9. 3)JIGGERING UNIT
Then the cake is passed through plungmills where continuous cylindrical
moulds are released and then they as cut into required length by thread
cutters automatically or manually.
Then these moulds are shaped into required shape. By automatic jiggering
machine.

10. 4)FINISHING AND DRYING
All the articles are checked and defective ones are discarded.
Then they are placed into rotating wheel and adequate layer of mass is
removed without affecting articles.
Then they are tunnel drive cars and the cars led into them in drying
chamber , where steam pressure provide heating with in specific limits.

11. 5)GLAZING UNIT
Glazing operation
Sanding operation
Stamping operation

12. 6)FIRING UNIT
The firing operation is done in the kiln where continuously one car is
entering from entrance door and one exit out through exit door. By
passing though it there standard is tested.
7)ASSEMBLY SECTION
Application of paint
Preparing of cement mortar
Fixing of caps , pin and holders
Assembling of insulators

14. 8)TESTING UNIT
a) ROUTINE TEST
 Physical verification test
 Routine mechanical test
 Routine electrical test
b) ACCEPTANCE TEST
 Verification of dimension
 Temperature cycle test
 Mechanical performance test
 Porosity test

15. 9)DISPACHING UNIT
T hen the ceramic insulators then dispatched to respective customers.

16. SUMMARY