1.Types of insulators:- 1) Pin insulators. 2) Solid post insulators.

3) Suspension insulators. 4) Hollow insulators. 5) Long rod single

piece porcelain insulators.Insulator is a substance which resist

the flow of electric current. 2. WHAT IS INSULATOR?

Hollow insulators are used for making of circuit breakers, Current

transformers, Potential transformers, Bushings, Lightning

arrestors.Suspension insulators are also used in transmission

above 33 kv. Solid post insulators is used for substation

requirements. Pin insulators are used in transmission up to 33

kv system. 3. Use of insulators

Its core diameter is up to 100 mm and its length is up to 1 m to 2

m long. It is used for transmission of electrical lines. It is

widely used in Europe and Germany but now-a-days it is

frequently used in India also. Long rod single piece porcelain

insulators:- 4. Contd…

Dispatch.Quality. Production. Design. 5. Manufacturing

process

Approval of drawing.Drawing is prepared by using software

AutoCAD. It produces a drawing as per technical specifications

required by the customer. 6. Role of design department

It is a batch process. Used for slurry preparation. Alumina. •

Ball Mill:- Quartz. Feldspar. China Clay. Raw materials

used:- 7. Process includes during manufacturing

Used to form pug.Pressure is 680 mm of Hg. Cakes transfer

into pug mill through conveyor into hopper. Used to form cake.

• Pug Mill:- Pressure is 250-300 kg/cm². Filter Press:- 8.

Contd..

Computerized Numerical Control machine is used for shaping

as per drawing. Penetrometer is used for checking hardness. •

Shaping:- 16 % to 17 % moisture presents in pug after drying.

Process running for 60 to 70 hrs. for pug drying. Voltage

supplied- 660 v Pug Electric Dryer:- 9. Contd…

Gravels sprays on top and bottom outer diameter. Insulators

dips into the glaze. Maximum temperature is 140° C for 400

hrs. • Glazing:- Shaped insulators keeps in dryer to reduce

moisture up to 0.1 % to 0.4 %. Dryer:- 10. Contd…

Shrinkage- 11 to 14 % Firing continues for 24 hrs. Minimum

temp. is 50° C and Maximum temp. is 1235 ° C. High speed

diesel or Propane gas is used for firing. Insulators are fired

after glazing. Kiln:- 11. Contd…

Machine used- Total cutting m/c and CuttingCutting and

Grinding:- 12. Contd… & Insulators cut at required height as

per drawing.Grinding m/c.

Cement injecting process is used for joining of metal part with

insulator. Metal parts made up of malleable cast iron used.

Jig is used for assembly purpose. Assembly:- 13. Contd…

Electrical test at voltage 45 KV for hollow insulators. Tensile

test for Long rod insulators. Pressure test for hollow insulators.

Bending test for Solid post insulators and hollow insulators.

Testing:- 14. Contd…

Final inspection. QC team verified the height of insulators after

cutting, assembly process, testing load of fired body. QC team

checks the viscosity of glaze, strength of body, shrinkage of

unfired body. Quality Control:- 15. Contd…

Dimensional Inspection like height of insulator, core diameter,

creepage distance etc. Creepage distance- 16 mm/kv to 31

mm/kv, it varies as per polluted area. Visual inspection for any

shed defect, cracks etc. Final Inspection:- 16. Contd…

Packing17. Contd… & Despatch to the customer end.

Packing of insulators as per customer requirement. It is a duty

of warehouse department. Despatch:-

18. Thank you

MANUFACTURING OF INSULATORS AT BHEL(IP) Jagdishpur plantPresentation Transcript

1. DATED :14.6.12 – 15.67.12UNDER GUIDENCE:

PRESENTED BY:MR. M.K.SINGH AMBESH SINGH(QUALITY

DEPT.) ME 4th YEARBHEL(IP) R.R.S.I.M.T.JAGDISHPUR

AMETHIA PRESENTATIONON“PRODUCTION PROCESS IN

MAKING INSULATOR”ATBHARAT HEAVY ELECTICAL

LIMITED(INSULATOR PLANT)JAGDISHPUR(U.P.)

EXPORT TO MIDDILE AND EAST AFRICAN COUNTRIESR.P.

GOENKA GROUP OF INDUSTRIESSTATE ELECTRIC

BOARDPOWER GRID COOPERATION OF

INDIANTPCBHEL (IP)BHEL (IP) IS LEADING

MANUFACTURER OF HIGH TENSION INSULATORSAND

DISTRIBUTION INSULATORS.THE PLANT IS EQUIPPED

WITH HIGHLYSOPHISTICATED PLANT AND

MACHINARY.MAJOR CONSUMERS OF BHEL IP

INSULATORS ARE:BHEL (CSU)2. Bharat Heavy Electricals

Limited is the largest Engineering and ManufacturingEnterprise

of its kind in India established in 1964 . It ranks amongst the

leadingmanufacturers of power plant equipment in the world. It is

also one of theNAVRATNA industries.JAGDISHPUR UNIT OF

BHEL IS DIVIDED IN TWO MAIN UNITS:

Strain typeSuspended typePin type3. The insulators are

used in over head lines for providing insulation to the

powerconductors from ground. They are made from

porcelain ,ceramic and toughenedglass .There are three type of

insulators used in over headlines:

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

5. MANUFACTURING PROCESS OF INSULATORS1. Storage2.

Slip house3. Jiggering Unit4. Finishing Unit5. Glazing Unit6.

Firing Unit7. Assembly Unit8. Testing Unit9. Dispatching Unit

6. 1)STORAGEThe different raw materials used for

manufacturing of insulators are storedin the identified bin. They

are :-a) Clayb) Quartzc) Brown glazed) Talke) Feldsparf)

Pyrophyliteg) Felciteh) Pebbles

7. 2)SLIP HOUSEa)Weighting:For preparing a body slip in 5 ton

ball mill are-Quartz - 1053kgFeldspar - 603kgPyrophylite -

653kgClay - 387kgFelcite - 201kgPebbles - 157kgb )Crushing of

raw material in BALL MILLS.

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 UNITThen the cake is passed through

plungmills where continuous cylindricalmoulds are released and

then they as cut into required length by threadcutters

automatically or manually.Then these moulds are shaped into

required shape. By automatic jiggeringmachine.

Then they are tunnel drive cars and the cars led into them in

dryingchamber , where steam pressure provide heating with in

specific limits.Then they are placed into rotating wheel and

adequate layer of mass isremoved without affecting articles.All

the articles are checked and defective ones are discarded.10.

4)FINISHING AND DRYING

Stamping operationSanding operationGlazing operation11.

5)GLAZING UNIT

Assembling of insulatorsFixing of caps , pin and

holdersPreparing of cement mortarApplication of paint12.

6)FIRING UNITThe firing operation is done in the kiln where

continuously one car isentering from entrance door and one exit

out through exit door. Bypassing though it there standard is

tested.7)ASSEMBLY SECTION

Porosity test Mechanical performance test Temperature cycle

test Verification of dimension Routine electrical testb)

ACCEPTANCE TEST Routine mechanical test Physical

verification test13. 8)TESTING UNITa) ROUTINE TEST

14. 9)DISPACHING UNITT hen the ceramic insulators then

dispatched to respective customers.

15. SUMMARY