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/cm. 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 140C 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 50C 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 PRESENTATIONONPRODUCTION PROCESS IN
MAKING INSULATORATBHARAT 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