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SEMINARANDPROJECT
REPORTSON
ELECTRICAL
ENGINEERING
Dearfriends..!!!Inthethirdyearofurenggcourseurequirestopresentaseminaronanyneworrecent
technologybasedonelectricalengg.Sowehavegivenualistsofseminartopicsandseminarreports.
Inthesummervacationof3rdyruhavetodotrainingofminimum4weeksfromanyelectricalcompany.
sowehavepresentedsometrainingreports

Sunday,September25,2011

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reportonBHELIPjagdishpur
1.INTRODUCTIONTOBHEL
BHEL is the largest engineering and manufacturing enterprise in India in the energy
related infrastructure sector , today. BHEL was established more than 40 years ago,
ushering in the indigenous Heavy Electrical Equipment industry in India a dream that
has been more than realized with a wellrecognized track record of performance.
Establishedinthelate50s,BharatHeavyElectricalLimited(BHEL)is,today,anameto
reckon with in the industrial world. It is the largest engineering and manufacturing
enterpriseofitskindinIndia,andoneoftheleadinginternationalcompaniesinthepower
field.
Established in the late 50s, Bharat Heavy Electrical Limited (BHEL) is,
today,anametoreckonwithintheindustrialworld.
FirstItWasIncorporatedIn1964with3PlantsLocatedAt
(1)HYDERABAD
(2)TIRUCHY
(3)BANGALORE.
SecondGenerationPlantsWereSetupInMid70sAt
(1)JHANSI
(2)RANIPAT
(3)TIRUCHY
(4)BANGALORE
(5)HARIDWAR.

1.1MANUFACTURINGUNITSOFB.H.E.L
Firstgenerationunits:
BHOPAL:HeavyElectricalPlant
HARIDWAR:HeavyElectricalEquipmentPlant
HYDERABAD:HeavyElectricalEquipmentPlant
TIRUCHY:HighPressureBoilerPlant
Secondgenerationunits:
JHANSI:TransformerandLocomotivesPlant
HARIDWAR:CentralFoundryandForgePlant
TIRUCHY:SeamlessSteelTubePlant
Unitsthroughacquitionandmerger:

BANGALORE : Electronics division and Electro

porcelain
division

Newmanufactureunit:
RANIPAT:Boilerauxiliariesplants
JAGDISHPUR:Insulatorplants
RUDRAPUR:ComponentsandFabricationPlants
BANGALORE:Industrialsystemgroup

BHELisgrowingconcernstomeetthechangingneedsofthenationhas

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1.
Introduction...
reportonBHELIPjagdishpur
1.INTRODUCTIONTOBHEL
BHEListhelargestengineering
andmanufacturingenterprisein
Indiaintheenergyrelated
infrastructuresect...
STATCOM
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takenitbeyondpowerintothetotalgamutofenergy,industrialandtransportation
BHEL is able to offer a total services in each of these fields. Its manufacturing
capabilityissupportedRandSdivisionatHyderabadworkcloselywithresearch
and development cells at various units and welding Research institute in
Tiruchinapalli.
BHEL offers over 180 products and provides systems and services to meet the
needs of core sectors like: Power, Transmission, Industry, Transportation, Non
Conventional Energy Sources, Oil & Gas Exploration & Telecommunication. With 14
Manufacturing Divisions wide spread Regional Services Network and Project Sites all
overIndia&abroadandwithanexportpresenceinmorethan50countries,BHEListruly
IndiasIndustrialambassadortotheworld.AllmajorManufacturing,ErectionandService
unitsofBHELhavebeenawardedISO9000certification.
BHEL is the largest engineering and manufacturing enterprise in India in the
energyrelated/infrastructure sector, today. BHEL was established more than 40 years
ago, ushering in the indigenous Heavy Electrical Equipment industry in India a dream
thathasbeenmorethanrealizedwithawellrecognizedtrackrecordofperformance.The
companyhasbeenearningprofitscontinuouslysince197172andpayingdividendssince
197677.
BHELmanufacturesover180productsunder30majorproductgroupsandcaters
tocoresectorsoftheIndianEconomyviz.,PowerGeneration&Transmission,Industry,
Transportation, Telecommunication, Renewable Energy, etc. The wide network of
BHEL's 16 manufacturing divisions(two new added,CSU&FP), four Power Sector
regional centers, over 100 project sites, eight service centers and 18 regional offices,
enables the Company to promptly serve its customers and provide them with suitable
products, systems and services efficiently and at competitive prices. BHEL is the
largestengineerandmanufacturinginthefieldofheavyelectricalinIndiaandamongthe
leadingpowerequipmentsmanufacturesintheworld.BHELhaspresenceincoresector
like power, industry, transportation, oil and gas, telecommunication, defense and non
convectional energy source from concept of commissioning. BHEL products and
systemshavebeenexportedtoover52countriesworldwide.
BHEL has continuously contributed dividends to the government. BHEL also
receivedExcellentratingfor9yearsconsequentlymemorandumofundertakingtargets
withGovernmentofIndiaandhasconferredthepricestatusofaNavarathnaCompany
anothermajorcontributionofBHELtothenationisbythewayofitsinvolvementinthe
social development work. Such as adoption of backward villages, buildings and running
of schools, medical centers providing selfemployment facilities for windows,
handicappedpersonsetc.
The greatest strength of BHEL is its highly skilled and committed 44,500
employees.Everyemployeeisgivenanequalopportunitytodevelophimselfandgrowin
hiscareer.Continuoustrainingandretraining,careerplanning,apositiveworkcultureand
participate style of management all these have engendered development of a
committed and motivated workforce setting new benchmarks in terms of productivity,
qualityandresponsiveness.
BHEL has acquired certifications to Quality Management Systems (ISO 9001),
Environmental Management Systems (ISO 14001) and Occupational Health & Safety
Management Systems (OHSAS 18001) and is also well on its journey towards Total
Quality.
BHEL has Installed equipment for over 90,000 MW of power generation for Utilities,
CaptiveandIndustrialusers.Suppliedover2,25,000MVAtransformercapacityandother
equipmentoperatinginTransmission&Distributionnetworkupto400kV(AC&DC).
Supplied over 25,000 Motors with Drive Control System to Power projects,
Petrochemicals, Refineries, Steel, Aluminum, Fertilizer, Cement plants etc. Supplied
TractionelectricandAC/DClocostopowerover12,000kmsRailwaynetwork.Supplied
overonemillionValvestoPowerPlantsandotherIndustries.
Duringthefinancialyear(200405),BharatHeavyElectricalLimited(BHEL)has
achieved 110% of CEAs target of commissioning by adding 3548 MW to the national
grid.Thiswasmadepossiblebecauseoftheadvancedcommissioningofa500MWunit
(Rihand3),notintheCEAsplanforthatperiod.Withthisthecompanyhasonceagain
demonstrated its capability and commitment to providing maximum value to its
customers
significantly,90%ofcoalbasedsetsaddedinthecountryduringtheyearwereofBHEL
make, while 80% of hydro MW addition and 79% of dieselbased MW addition was
contributedbyBHELsets.Evenduringthecurrentfiscal,BHELisfullygeareduptoadd
30 coal, hydro, nuclear and gasbased sets aggregating to 3712 MW to the countrys
generatingcapacity.
Inadditionduringthisperiod,73%ofelectricenergygeneratedbyutilitiesinthe
country from coal, nuclear and hydro based units was contributed by BHEL make sets,
eventhoughBHELsetsconstituteonly65%ofthetotalgeneratingcapacity.
BHEL also created a new benchmark in execution of thermal power projects,
with the synchronization of the 500 MW (unit 7) at NTPCs Ramagundam STPS in a
recordtimeofjust36monthsand10days,nearlythreemonthsaheadofschedule.This
resulted in substantial saving for the customer in terms of the cost of the project and
additional generation of power. Similarly, BHEL created another national record in the
turnkeyexecutionofthermalpowerprojectslastyear,bycommissioningthe2x250MW
TauDeviLalThermalPowerStationofHaryanaPowerGenerationCorporationLimitedin
just34months.Alsoanewbenchmarkwassetwiththecommissioningofboththeunits
within a span of only 4 months. It is worth mentioning that even one months advance
commissioningofa500MWunitresultsinanapproximatesavingofaboutRs.75Crores
totheutility.
Inordertocopewiththecountrysambitioustargetcapacityadditioninthe11thand12th
plan,BHELisgearinguptoenhanceitsequipmentmanufacturingcapacityfrompresent
10,000MWto15,000MWannuallybyMarch,2008.Thisshouldenablethecompanyto
playamajorroleinpowergeneratingcapacityadditionprogramofthecountry.

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1.2SYSTEMANDSERVICES:
1.2.1POWERGENERATIONSYSTEMS:
BHEL has commissioned more than 800 Nos. utility and industrial sets totaling to over
50,000 MW equivalent generating capacity. BHELs share in utility generating capacity
wasapproximately64%oftheinstalledcapacityinIndiainMarch1993.Presently,BHEL
hascapacitytosupplypowerequipmentequivalentto7000MWperyear.

(A)THERMALGENERATION:
TheunitsizesofutilitystationsinIndiarangefrom30MWto500MWBHELhassofor
being responsible for over 2000 of these installations accounting for over 40000 MW of
installed generating capacity (utility) which include sets up to 500 MW capacity. The
technology for manufacture of turbo generators comes from a comprehensive technical
calibration agreement with Scienes AG of Germany. BHEL manufactures steam
generator as per technology of M/S ABB Combustion Engineering of the USA. This
technologyhasbeenacquiredthrough20yearsofcollaboration/licenseagreement.Both
these collaboration covered unit ratings up to 1000 MW. Operating in an environment of
hightechnologyandseverecompetitionasBHELdoes,thecompanyhasperformtostay
abreast with the technology leaders in the world. It is in recognition of such imperatives
that BHEL has technology tieups around the world for a variety of power station
auxiliaries as well.BHEL has a well chalked out programmed to assimilate, adapt and
modifysuchacquiredtechnologytosuitdifferingeconomic,developmental,geographic&
climatic requirement. The company has also a fullfledged Research and Development
Division which undertake fundamental and applied research in power and related fields.
Research is being carried out on nonconventional energy sources as well. Several of
these efforts such as those in the areas of fluidized Bed Combustion, Solar and Wind
Powerhavealreadyresultedincommercialventures.

(B)HYDROGENERATION:
BHEL has supplied Hydro Sets upto 165 MW rating and 200 MW sets are under
manufacture,BHELhasfacilitiestomanufactureandinstallsetsofevenhigherratingas
perspecificcustomerrequirements.Italsosuppliesturbinesforlowheadminiandmicro
hydro stations to meet the needs of rural and backward areas located in the remote
corners of the country. So far, BHEL has commissioned mire than 200 Hydro Sets of
varioustypesand
capacitiestattlingtoabout12000MW.

(C)NUCLEARGENERATION:
Indias first wholly indigenous Atomic Power plant at Kalapakkam near Madras is
equipped with two sets of power generation equipment of rating 235 MW each supplied
by BHEL. Subsequently, another two sets of similar rating have been commissioned
successfully at Narora. BHEL is now manufacturing sets of 500 MW rating for nuclear
powerstations.

(D)GASTURBINESBASEDGENERATORSPLANTS:
TodayBHELisfullyequippedtosupplysimple/confinedcycle/cozenplantswithvarious
frame sizes of gas turbines of unit rating upto 200 MW. BHEL has collaboration
agreements with two leaders of gas turbines technology in the world namely general
electric, USA and SiemensAG, Germany. The agreement with GE, USA covers rating
from4.6MW(ISO).TheSiemens agreementcoversunitratingfrom130MWto200MW.
SofarBHELhas
Suppliedmorethan33nos.Hasaturbine.Alltheseturbineshavebeensuppliedfromour
Hyderabadplantbasedongeneralelectric,USAtechnology.BHELhasbaggedordersfor
two gas turbine based projects in Malaysia, commissioning schedule of 6 10 months.
The first project has already been commissioning in 6 months time. While the gas
turbinesof
GE/USAdesignaresuppliedfromHyderabadplant.Withtheplants(i.e.Hyderabadand
Hardwar)arefullyequippedwithstateofmanufacturingandtestingfacilities.
BHEL is fully equipped to supply waste heat recovery boilers from their
Tiruchirapalliplant.BHELhaveanongoingcollaborationagreementwithM/SHenryvolt,
USAfortheWasteHeatRecoveryBoilers.BHELissupplyingWHRSGSfoe6X30MW
gasturbinesforDelhielectricsupplyundertaking,and817MWDadriProjectofnational
thermalpowercorporationlimitedbesidesthoseforotherpowerstations.
Turnkeypowerstations.
Combinedcyclepowerplants.
Cogenerationsystems.
Modernizationandrehabilitationofpowerstations.
Erectioncommissioning,operationandmaintenanceservices.
Sparesmanagement.
Consultancyservices.

1.2.2TRANSMISSIONSYSTEMS:
In addition to equipment for generating of power, BHEL supplies a variety of equipment
fortransmissionandutilizationofpower.Thecompanyhasalsoundertakenanumberof
turnkeysubstationcontractsforvoltageratingupto400kvclass.KeepingwiththeKM
long HVDC (High voltage direct current) transmission line project line for reliable and
efficienttransmissionofbulkpower.
BHEL has in house capability to supply most of the equipment like power
transformer current transformer, voltage transformers switches, insulators etc., and also
possessesinhousemoderntestingfacilities.BillionsofBHELmanufacturedinsulatorsof

various ratings up to 160 KN are satisfactory service in many countries namelyTurkey,

Egypt,Malaysia,Iran,Iraq,USALibya,TanzaniaDubaiandcourseIndia.
Substationsswitchyards.
HVDCtransmissionsystems.
Shuntandseriescompensationsystems.
Powersystemstudies.
Erectioncommissioning,operationandmaintenanceservices.
Consultancyservices.

1.2.3TRANSPORTATIONSYSTEMS:
For over quarter of a century, BHEL has been supplying drives and control for traction
equipmentmainlytotheIndianRailway,whichisthethirdlargestRailwaynetworkinthe
world.Today,65%oftherollingstockinIndiancontainselectricofBHELmakesuchas
traction motors, traction generators/alternators, and transformers. The company has
lately moved from the position of supplier of electrics only to supplier of complete
locomotives
bothdieselselectricaswellasA.C.Locos.Theurbantransportationproblemdemands
different solutions and BHELs contribution extends to underground tube, light rail and
batterypoweredroadvehicles.
Tractionsystems.
Urbantransportationsystems.
Erectioncommissioning,operationandmaintenanceservices.
Consultancyservices.

1.2.4INDUSTRIALSYSTEMS:
The industry Sector of BHEL offers diverse items such as Transformers, Switcher,
Rectifiers, Insulators, Capacitors, Control Gear, Valves Compressors, Pumps, Piping,
Motors,Industrialturbinesoilrigsandsemiconductordevicestomeetthevaryingneeds
ofindustry.
Industrialdrivesandcontrolsystems.
Erectioncommissioning,operationandmaintenanceservices.
Sparesmanagement.
Consultancyservices.

1.3SERVICES:
1.3.1PROJECTENGINEERING:
The total engineering for thermal power stations is undertaken by a core group project
engineering management. With over 500 engineers and supporting staff, this division
offers specialized service in different technical disciplines and undertakes engineering
worksrelatingtooptimizationofcycleconfigurationselectionsofparametersanddesign
ofsuitablesystemforpowerstationswithatotalMWcapacityof30000andiscurrently
involvedin
severalturnkeyprojectincludingstationshaving500MWunitsize.

1.3.2CONSTRUCTIONSMANAGEMENT:
BHEL has a fullfledged construction management division to undertake erection work.
This division well organized with over 500 experienced engineers,1000 technicians and
1300 skilled workers besides construction equipment valued at over 40 million US
Dollars.
1.3.3SERVICEAFTERSALES:
BHEL extends its supply and construction scope with service such as commissioning
field engineering performance monitoring trouble shooting operation and maintenance.
Renovation modernization and rehabilitation works of aged power stations are also
undertaken.BHELhasaseparatesparegroupresponseforinsuringreadyavailabilityof
essentialsparestoPowerstations.

1.3.4PROJECTSMANAGEMENT:
The project management division of BHEL coordinates th4 entire range of BHEL
activities in relation to thermal power plant project and is responsible to the purchasing
organization for compliance of the specifications. Entrusted with the overall coordination
of the project the division initiates, directs coordinates, supervises and control all
activitiesthatarenecessaryfortheperformanceoftheprojectrightfromtheconception
stageuntilthecontractualobligationsarefullydischarged.BHELoffersawidespectrum

ofproductsandservicesforcoresectorslikepowertransmissionindustry,transportation,
oil&gastelecommunicationetc,deseedssupplyofnonconventionalenergysystems.It
hasalsoembarkedittootherareasincludingdefence&aviation.

1.4COMPANYOBJECTIVES
Adynamicorganizationisonewhichkeepsitsaimhighadoptsitselfquicklyto
thechangingenvironment.SohereweareinBHEL.

Figure1.1:VisionandMisson

1.4.1VALUES:
Strikeadherencetocommitments.
Fosterlearning,creativityandteamwork.
Ensurespeedofresponse.
Respectfordignityandpotentialforindividual.
Loyaltyandprideinthecompany.
Zealtoexcelandzestforchange.
Integrityandfairnessinallmatters.
Mostofthemhavebeenrephrased.
"Zest for change" has been added as change has been integral with success
andtherateatwhichchangeisneededisveryhighcomparedtoearlierperiod.

2.BHELINSULATORPLANT,JAGDISHPUR

AUNITOFBHEL
Insulator Plant, Jagdishpur was inaugurated on 3rd March,1984 by then Prime
Minister of India Late Smt. Indira Gandhi , as 11th manufacturing unit of BHEL in
Sultanpur District, 77 Kms. Away from Lucknow on LucknowSultanpur highway.
BHELs glorious experience in the Ceramic field with technical collaboration with M/s.
NGK,Japan,theworldleaderininsulatortechnology,setthepaceforthecommissioning
of this plant. This unit has been provided with the most modern and sophisticated
facilities.
WithaviewtoensurefinancialviabilityofInsulatorPlant,Jagdishpur,theUnitof
BHELplannedtodiversifiedtotheproductionofIndustrialCeramicsnamelyCeralinin
the year 198990. The Ceralin production for commercial use was started in 199394.
The ceralin was the product being manufactured in BHELs Electro porcelain Division,
Bangalore and Insulator Plant Jagdishpur got a technologically established and
commercializedproduct.
ForincreasingtheproductionofceralinBHELInsulatorPlantinstalledamodernBell
type HighTemperature Kiln(NEUTEC BIKLEY) in the March 2009.This HTK has firing
capacityof4to5ton.
BHEL Insulator Plant, Jagdishpur is the leading manufacturer of High Tension
Porcelain Insulators and Distribution insulators like Bobbin/Shackle, Guy/Stay/Strain,
Pin, Cap & Pin type Post Insulators in the country. They are equipped with highly
sophisticated plant and machinery. This division also offers Wear Resistant High
AluminaCeramicLiningmaterialforPower,Steel,CementandMiningIndustriesaswell
asawiderangeofIndustrialCeramics.
BHEL Insulator Plant, Jagdishpur has attained ISO 9001 certification in 1994,
ISO 14001 and OHSAS 18001 certifications in 2002 for its well established systematic
productionsystems,standards,environmentalmanagementandsafetymanagement.
In addition of these BHEL IP has got certification of merit in RKBNQA in the
year2009.Thisshowsthededicationofeachindividualsofunitforthequalityofworks
andproduct.
The insulator plant BHEL, catering to electric power transmission business by
wayofmanufactureandsupplyofdiscinsulator.Presentlytheplantisgearedtoproduce
19 thousand tons of disc insulators annually and one thousand tons of Ly. of insulators.
Over the year lot of technological innovation have taken place in the plant which has
streamlining of manufacturing processes & has taken it in to the level of best industry.
New type of disc insulator has also been introduced periodically and today it
manufactures disc insulators up to 160Kn.Stength ranging from normal to antifog type.

Theplanthastilldateexecutedmanyprestigiousexportcontractsandhassupplieddisc
insulatorstoTurkey,Malaysia,Trinidad&Tobago,Ghana,andNigeriaetc.
Since 1994, low tension types of insulators have also been introduced in the
product range in addition it supplies to domestic market quantities have also been
exported to countries like UK & South Africa. In present area of liberalization the
companyhasnotonlygonefordiversificationbutalsohastakenconcretemeasuresfor
organizational and product improvement by ISO9001 certification and adopting iqm
approach. In the present world an attempt has been made to system erotically analyze
the export market requirements of insulators and identify the product forming bulk
exports. The world market scenario of insulators imports have been presented with a
viewtoprovidestrategicglobalmarketinformationforinsulatorexports.
BHELSmorethan40yearsexperienceintheceramicfield,blendedwiththatof
NGK, Japans world leader in insulator technology, set the pace for been provided with
the most modern and sophisticated facilities, and was commissioned in a record line of
18thmonths.
Insulator plant Jagdishpur has developed into one of the Indias disc insulator
manufacturing centers with the most streamlined layout and modern technology.It6 has
provisionstocopewithlatestadvancesintheceramicfield.

2.1OBJECTIVESANDGOALSOFINSULATORPLANT:

1. Appropriately Integrate Manufacturing withTechnology development and

furthertechnologydevelopmentwithmarketing.
2.ThrustonExportMarketing.
3. To maximize the Business in CeramicsArea by Business Development,
Engineering
and
Technology
Management
(Technology
acquisition/Technologydevelopment/Jobtojobtieupetc.).
4.Toensureearningoncapitalemployedthroughefficientandeffectiveuseof
resourcesandenhancestakeholdersinterests.
5. ToproducequalityproductsinthefieldofCeramicsandattain&sustaina
goodmarketshareinCeramicIndustryofIndia.

2.2PRODUCTRANGE:
DiscInsulatorsupto210kNstrengthfortransmissionlinesupto765kVAC,
500KVand800kvHVDCDiscInsulators.
HollowBushingsfor11kvand33kvkVSystems.
Busbarsupportfor11kvand22kvline.
CeramicLiners(Ceralin)forwearresistantapplications.

2.3 MAJOR RIVALS OF BHEL INSULATOR PLANT,

JAGDISHPUR:
Jaishreeinsulators,kolkata(birlagroup)
Wsinsulators,kolkata(westbengal)
Moderninsulators,chennai
Iec,kolkata(westbengal)
Bathindaceramics,punjab
Hitech,khurja(u.p.)
Powertech,khurja(u.p.)

2.4MAJORCUSTOMEROFBHELIPJAGDISHPUR:
Jagdishpur insulator plant has some important customer which are state
electricity board, government organizations, public sector units and private
customerandIndianrailways.
2.4.1STATEELECTRICITYBOARDS
UPPCL
MPSEB
GEB
PSEB
KSEB
KPTCL
TNEB
MSEB
2.4.2PUBLICSECTORUNITS

POWERGRID
NTPC
NHPC
DVC
NLC
GovernmentOrganizations
Govt.ofTripura

Govt.ofJ&K
Govt.ofMijoram
Govt.ofManipur

2.4.3PRIVATECUSTOMERS:
JyotiStructuresLtd.
JSPL(JindalSteelPowerLtd)
AssociatedTransrailStrucruresLtd
RPGTransmissionLtd.
TataProject
RamjiPowerConstruction
EMC(ElectricalManufacturingCompany)
KPTL(KalputraPowerTransmissionLtd.)
DevangElectricals

3.PRODUCTIONOFDISCNSULATORS

Figure3.1:Discinsulator

Figure3.2:Internalstructureofdiscinsulator

3.1TECHNICALCHARACTERISTICS:
Rating:45kNto210kNEMS
CreapageDistance:192mmto380mm
LockingDevice:R/WTypeinPB/SS
GlazeColor:Brown/Grey
Applications:TransmissionLinesfrom11kVto765kVAC&500kV
and800kVHVDC,Substations

3.2PROCESSFLOWCHARTOFDISCINSULATOR
MANUFACTURING:
WeighmentofRawMaterialsinSlipHouse
SHX
Ballmill
OilInspection
LoadingKILN
Glazing
TunnelDrier
Finishing
Blunger
Assembly
Curing
MetalParts
SecurityClips&PackingCrates
Scrap
VisualInspection
Testing

BituminousPaint,Thinner
ThermalCycle
HydraulicTesting
Porosity
Test Spray
Packing&Storage
Dispatch

Filterpress
&Pugging

Jiggering

Jiggering:FormingProcess
Finishing:Dimensionalcontrol&Surfacesmootheningtoenhance
Extrusion:FilterpresscakestoBlanksGlazeadherence
Drying:RemovalMoistureto<1%
Inspection:Segregationofdefectiveinsulators
Glazing:Applicationofglaze(Brown/Grey)
Firing:Tunnelkilns/batchKilns
Inspection:Segregationofdefectiveinsulators
HydraulicTesting:WeedoutdefectiveinsulatorsatHeadportion
ThermalTest:Withstandthermalshock
Assembly:JoiningofMetalparts(CapandPin)withCement
Curing:Hardening/Strengtheningofcement
FinalTest:MechanicalTest(At40%ofrated)andHighvoltage,
HighFrequencyTest

PackingandDispatch

Figure3.4:Processflowdiagram

3.3SLIPHOUSE:
Thesliphouseperformsthefollowingoperations.Allthesematerialsareusedindifferent
quantities for different type of insulators that are manufactured and demanded by the
customers.
Therawmaterialsrequiredformanufacturingtheinsulatorsare:

Figure3.3:Processflowchart
FIRSTCHAEGE:

Quartz
Feldspar(stonepowder)
Pyrophillite
Riverpebbles
Bikanerclay
Felsites
Alumina
SECONDCHARGE:Thesearedifferenttypeofclay.
Thanclay
Ellureclay
Ballclay
Chaibasaclay
Japanball(J.B.)clay
Chinaclay
Figure3.5:Blockdiagramofsliphouse

3.3.1WHEREHOUSE:
The production in the BHEL runs 365 days, and it is a continuous process. Here raw
materials are tested before manufacturing the insulators so that raw materials obtained
fromplacessatisfiestheirrequirements.

3.3.2CRUSHINGPLANT:
Above said materials other than clay are available in the stone form. Crushing plant is
used to crush these raw materials into powder form and also it is used to powder the
rejectedonesforrecycling.

3.3.3WEIGHMENT:
The raw materials are required to be mixed in different composition. Therefore
weighment of raw material is done. 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.Then the weighing card is attached to
thelot.
Asampledataforpreparationofsuspensionbodyslipina5tonballmillforthe
firstchargeareasfollows:
Quartz
Feldspar
Bikanerclay
Pyrophylite
Felcite
Pebbles

1053kg
603kg
387kg
653kg
201kg
157kg(duethepresenceof
previously
chargedpebblesintheballmill)
Table3.3.1:Compositionofslip

3.3.4CHARGING:
Itisapreproductionsection.Beforetheactualproductionstartstherawmaterialshaveto
undergo a certain specific process. In the slip house the raw materials are got from the
material management department. These raw materials are mixed into certain
compositionaccordingtocustomerneedthenthesearefedtoballmills.

3.3.5BALLMILL:
Abovesaidmaterialsotherthanclayareavailableinthestoneform.Crushingplantis
usedtocrushtheserawmaterialsintopowderformandalsoitisusedtopowderthe
rejectedonesforrecycling.Therawmaterialsarerequiredtobemixedindifferent
composition.Thereforeweighmentofrawmaterialisdone.
Weighted raw materials including clay are mixed with sufficient water i.e. 50% of raw
materialsand50%waterandgrindingintheballmillsfordurationof(17+3)hoursitisa
continuousprocessroundtheclock.Inthefirstphaseofchargingfeldsparandquartzis
mixed with water for 17 hour, after that clay is mixed for next 3 hours. The materials
obtainedintheballmillingprocessarecalledsliporceramicslurry.

3.3.6RIVERPEBBLECHARGING:
For initial charging of river pebble in the ballmill after rolling large ,medium and small
pebbles are collected as per standard samples and weighted as per specification
number(PPSL:0100R2)andpebblesarechargedasperthequantityspecified.
Therawmaterialsareloadedpercompositioninto"ballmills".Inballmills'river
pebble' are put as grinding media. When ball mill is operated the grinding media and
rawmaterialproducedthefilepastecalled'slip'.Theceramicslurrygotfromtheballmill
is fed to the vibrator screens to check for the correct accumulation throughout the
materials and also to remove solid particles. Then the material will be having too less
impurities and then goes for filter press to extract water by pressing that ceramic body
withhighpressureThisslipistheinputforthe'filterpressestoproducedthe'cake'.This
cakeisoutputofsliphouseandservesasinputformanufacturingJiggering.

3.3.7PREPARATIONOFFIRSTCHARGEBODYSLIP:
Weighedquantityoffirstchargedrawmaterialsischargedintotheballmillbyattaching
aconetoitsholefromthechargingholeontheplatform.Thepebblesarecleanedwith
waterbeforechargingandthenspecifiedquantityofwaterischargedintotheballmill.
Generallychargingtakes12hoursandballmillruns1416hour.

3.3.8PREPARATIONOFSECONDCHARGEBODYSLIP:
Weighedquantityofsecondchargeischargedintotheballmillwithrequiredquantityof
waterafterpreparationoffirstchargebodyslipandtheballmillisrunforspecifiedtime.
Thentheslipisdischargedintothemixingtankandisagitatedcontinuously.

3.3.9BLUNGINGRETURNSSLIP:
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
homogeneousslip.

3.3.10VIBROSCREENING
SEPERATION/DEMAGNITIZATION:
Here the slurry is transferred to the tank from the ball mill to remove the unwanted
materials like threads of the plastic bags in which the raw materials are stored, wooden
pieces through vibration and electromagnetic separation. This tank is called discharge
tank.

3.3.11SLIPAGITATING:
Afterscreening,theceramicslurryistransferredtoanotherspeciallybuiltbankcalledtop
tanks. From this it passed through two vibratory screens which will be rotating
continuouslytoavoidaccumulationofrawmaterialsatthebottomandafterontop.Then
the mixture is fed to Ferro Filter for removing the iron particles. Finally the fresh slip is
collectedinthefreshtankorstoragetank.

3.4PREPARATIONOFCAKE:
Theslipfromtheinitialtankispumpedintothepressusingplungerpumpandthen
adequatepressureisappliedtoturnitintoacake.Herethesliphouseworkiscomplete.

3.4.1FILTERPRESSINGDEWATERING:
Itisdewateringprocess.Inthisprocess80%ofthewaterisremovedfromtheslipsoas
to convert the slip into cake form using nylon clothes. In this process high pressure is
appliedbycompressingthemfrombothsides.

3.4.2PUGGING:
Itisadeairingoperationundervacuum.Thecakesarefilledintopugmillstoremoveair
bubbles present in the cakes. In the pug mill homogenous mixing of cakes takes place.
The product which comes out after pugging process is called as blanks. Blanks are
extrudedfromthepugmillsinthecylindricalformofdifferentsizesfordifferenttypesof
insulators.Inthisprocessthemoisturecontentisreducedupto22%.CylindricalBlanks
are shaped conically by pre shaping machine to facilitate Proper compaction during
formingprocess.

3.5JIGGERINGFORMINGOFDISCINSULATORS:
The input for Jiggering station is cake produced by slip house. The cake are fed into
'pugmill', which under vacuum homogenous Cake in cylindrical 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 or final die gives the final shape shell. These green stage shells are dried in
CD(chaindryer).Afterdryingtheseshellsaretakenoutofmodesandsendforfinishing.
PreshapingblanksareplacedintoMouldswhichinnersidehasliningofplaster
ofparisandshapedonAutomaticJiggeringMachine.ToavoidstickingbetweenTheDie
andthemould,amixtureofKeroseneoilandCoconutoilisusedasLubricant.
AluminumBronzeDiesmachinedandcarefullyprofilefinishedareusedtoShape
the insulators. Profile shaped by the Die will not be disturbed further. Insulators are
ensuredfordefectsfree.MouldwillhaveAluminumouterCasingforstrengthandliningof
Plaster of Paris porous material with water absorbing property which facilitates to
separatetheinsulatorssometimeafterFormingJiggering.

3.6DRYING:
InsulatorafterformingaredriedInChainDryersat30to35degreecentigradeforabout2
to3hourstofacilitateseparationofInsulatorfromthemouldeasily.
Thedifferentdryingstepsareasfollows:

3.6.1CHAINDRYER:
These dries are used for drying the disc insulators.After this process the insulators will
behavinglessthan15%moisture.

3.6.2BLANKDRYER:
Forhollowinsulatorandsolidcoreinsulatortheblanksproducedbypugmillsaredirectly
fed to these blank driers. For making the hollow insulators and solid core insulators the
hardness of blanks is very much necessary. Therefore blanks are dried to see that the
moisturecontentislessthan15%.

3.6.3MOULDRELEASINGOFDISCINSULATORS:
Insulators are separated from moulds over Aluminum Ring which supports Green
InsulatorandhelpsinhandlingtheInsulatorsatfurtherstages.Insulatorareloadedgently
to the Racks and moved to Humidity controlled storage chambers to attain leather hard
condition(storedfor10to12hoursat~60%Humidity ).

3.7OILINSPECTION:
After the disc insulators are dried from chain dryer, they will go for finishing operation.
Those processes give a perfect shape for the product and then the visual and oil
inspectioniscarriedoutforthequalityoftheproduct.

3.8FINISHING:
The article is placed on the rotating wheel and adequate layer of mass is removed
without affecting die formation. Dimensional control & Surface smoothening to enhance
Glaze adherence .Insulators of specified Hardness (Moisture content) finished for
Specified Dimensions likeHead diameter Head diameter and Thickness are the most
criticaldimensionsbeingmaintainedstringently.

3.9INSPECTIONSEGREGATIONOFDEFECTIVE
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
initiatingcorrectivestepsatpreviousstages.

3.9.1DEFECTSININSULATOR:
Figure3.6:Defectininsulator

3.9.2SOMEOTHERDEFECTS:
a.EHMMistaketakesplacedueHANDMISTAKINGbyworker.Thiscantake
placeduetocarelessness.
b.EFTItisfinishingdefect.Itcantakeplaceshapingprocess.
c.PHPinhomedefectduetojiggering.
d.RTRingtouchdefectduetopoorhandling.
e.EMTManufacturingdefect.

3.10TUNNELDRYERS(T.D.):

Thediscinsulatorafterinspectiongoesintotunneldryersforfurtherdrying.
Therearetwotunneldryers,eachdryershas5zonesoftemperatures.

Zone
Zone1

Temperaturerange

Zone2

48oCto62oC

Zone3

minimum70oC

Zone4

85to103oC(Heatingzone)

33oCto47oC

Zone5

minimum65oC
Table3.2:Temperaturerangeofkiln

In this process the moisture is removed through stream. After the drying each
product will have less than 1% moisture in it. This model of drying is called drying
chamber.

3.11GLAZING:
After the model drying is over all the types of insulators goes for glazing. 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 results in
improvedmechanicalandelectricalstabilitycharacteristics.
GoodInsulatorsareglazedinAutomaticGlazingmachines(AGM).SpecifiedSpecific
gravity, viscosity and thickness are maintained to enhance the Glaze impact on the
insulator.
SandingisdoneonpinportionandHeadportionofGlazedinsulatorstofacilitatebetter
gripwhilecementingtheMetalpartsandimprovesMechanicalcharacteristicsofthe
Insulators.

StampingIdentificationmadeontheinsulatorsbasedonthecustomerrequirements
andStandards.
3.11.1ADVANTAGESOFGLAZINGARE:
Goodlooking.
Additionalstrength.
Clusteringsurface.
Smoothsurface&longlife.

3.12FIRINGOFDISCINSULATOR:
3.12.1TUNNELKILNS/BATCHKILNS:
Glazedinsulatorsareloadedtowagonsandfiredattemperatureat1245to12550CinGas
FiredTunnelKilns.Thefiringworkisdoneinthekiln.Itisacontinuousprocessandthe
kilntemperatureandcycleismaintainedaccordingtotheinstructionsoftheE&D.Thisis
done to test and check the suitability of the product according to the specifications
mentionedduringthewholeprocess.

3.13INSPECTIONSEGREGATIONOFDEFECTIVE
INSULATORS:
After Firing 100% Inspection is carried to Identify Mfg defects, glazing defects, Loading
defectsandKilndefectsforAnalysisandtoinitiatecorrectiveactionsatpreviousstages.

3.14TESTINGOFINSULATOR:
Afterfiringtheinsulatorgoesfortesting.
Thevarioustypesoftestsare:

Hydraulicpressuretest
Thermaltest
Mallettest
Electricalflashovertest.

3.14.1HYDRAULICTESTING:
100%InsulatorsaretestedtoweedoutdefectiveatHeadportion.Inthistesta200
kg/cm2pressureisappliedattheheadportionoftheinsulator.

Figure3.7:Discinsulator

3.14.2THERMALTEST:
Withstand thermal shock, 70 degree centigrade difference between cold water and hot
watershouldbemaintain.Inthistestfirstofallinsulatorisplacedinthehotwaterfor15
minutes and then it drain into the cold water. During this test there should be no crack
comeintotheinsulator.

3.14.3ASSEMBLYOFMETALPARTS:
The metal parts, cup and pin are joined here. To join the metal parts there is a special
typeofcementknownasalkreetcementisused.Afterassembling,theinsulatorgoesfor
curing(drying)operation.Thedifferentkindsofcuringaresteamcuring(2andhalfhours),
hotwatercuring(3days)andaircuring(1day).

3.14.4MECHANICALTEST:
The complete insulator string along with its hardware fittings excluding arcing horn,
corona control ring/grading ring and suspension assembly/dead end assembly shall be
subjected to a load equal to 50% of the specified minimum ultimate tensile strength
(UTS) which shall be increased at steady rate to 67% of the minimum UTS specified.
Theloadshallbeheldforfiveminutesandthenremoved.Afterremovaloftheload,the
string components shall not show any visual deformation and it shall be possible to
disassemble them by hand. Hand tools may be used to remove cotter pins and loosen
thenutsinitially.Thestringshallthenbereassembledandloadedto50%ofUTSandthe
load shall be further increased at a steady rate till the specified minimum UTS and held
foroneminute.Nofractureshouldoccurduringthisperiod.Theappliedloadshallthenbe
increaseduntilthefailingloadisreachedandthevaluerecorded.

3.14.5ELECTRICALTEST:
Aftercuring,theinsulatorsaresetforfinalelectrictesting.Ifinsulatorsfailinthistest,it
burnsoutandthustheyarerejected.

Inelectricaltestingtheinsulatorispassedunderhighvoltagelineofratingnear
about 3 to 4 times of rated value for four minutes. If a yellow color light flame appears
acrosstheinsulatorthenitwillberejectedduetopoorflashovercapacity.Ifitisableto
withstandwithhighvoltagethenitislabeledbyagreensymbolandsendtodispatch.

3.15PACKINGANDDISPATCH:
The insulators, which are successful in the tests, are sent for packing section. The
insulators are well packed in crates to avoid damages during transportation and ease
smooth handling. Thus, the time taken for all this activities crushing to packing is 31
days.

4.MANUFACTURINGOFHOLLOW
BUSHINGS
Figure4.1:Hollowbushing
These are two main type of insulator for apparatus at sub stations.They are the hollow
porcelain used for the transformer bushings, and the subject insulators used for
supportingthebuslines.

4.1PRODUCTRANGE:Hollowbushings11kVand33kV

4.2PROCESSCHARTOFMANUFACTURING:
DISPATCH
RAWMATERIAL

WEIGHMENT

WETGEINDING

(BALLMILLING)

PUGGING

FILTERPRESSING

TURNING

DRYING

FIRING

LOADING

INSPECTION

TESTING

SLIPPURIFICATION

GREENINSPECTION

GLAZING

GRINDING

Figure4.2:Blockdiagramofmanufacturingofbushing
PACKING
After the formation of cake in the filter press,TESTING
the material is fed to pug mill.A blank is
formedwhichisthendriedinblankdryingchambertoreducethemoisturecontentbelow
1516%.Thenthematerialisgivenforturningwhereverticallatheisused.Afteradesired
shapeisattainedthenthemodelissendtomodeldryingchamber(MDC)todecreasethe
moisturecontentlessthan1%andthenitisglazed&fedtokilnsforfiring.

4.3PUGMILL:
The cakes obtained from filter press are automatically / manually fed into the pug mill.
The pug mill has three chambers namely primary chamber, vacuum chamber and final
chamber. In the primary chamber the hopper blades and single helical screws are
provided.Thecakeswhicharefedwillbechoppedintosmallbitsandpushedforwardby
the screw. The material comes to vacuum chamber thro slit plate. In the vacuum
chamber the required vacuum is maintained to remove any air pockets in the body.The
main purpose of the pugging is deairing and kneading for blank extrusion .The obtained
blanksarecutintorequiredsizeandaresenttoblankdryingchamber.

4.4BLANKDRYINGCHAMBER:
Themoisturecontentrequiredfortheblanksforshapingprocessisabout16%toturnthe
model. During drying, water evaporates slowly resulting in uniform shrinkage and
hardness.Itisnecessarytohavecontrolleddryingtoavoidstress.

4.5TURNING:
Theconditionedblanksareturnedonverticallathes(ManualandCNClathes).Theinner
surfaceofbushing,turnedbythehelpoflathesmachine.Thesmoothsurfaceisrequired
forthepurposeofsafeconductor.

4.6NATURALDRYINGBEFOREFINALDRYING:
Thehollowbushingisputupintheairfordryinguptosomeextent.

4.6.1FINALDRYING:
The articles are further dried in thermal fluid dryers and tunnel driers to less than 1%
moisturecontent.

4.7INSPECTINGGREENINSULATORFORDEFECTSAND
DIMENSIONCORRECTION:
Insulatorisinspectedbymanuallyanddefectedinsulatorhasbeenremoved.Bythiswe
cansaveourenergyandrawmaterial.

4.8GLAZING:
Glaze is prepared in the similar method as Insulator body slip is prepared, with some
changes in the composition. Metallic oxides are used to get the desired color of the
glaze.The physical properties of glaze i.e., specific gravity and viscosity are maintained
asperthespecificationatthetimeofapplicationonInsulators.

4.8.1GLAZED&FIREDINSULATOR:

Figure4.3:Greenandfiredinsulator

ASSEMBLY


4.9ASSEMBLYOFINSULATORWITHMETALPART:
The metal portion of hollow bushing is set in this process. The metal part is used to
connect from other auxiliary instrument. The metal part can be assembling by cement
pouringprocess.Inthisprocessthecementisfilledupbetweenmetalandinsulator.

5.ROUTINETESTS:
Mechanical,electrical,thermal,pressuretestsarecarriedoutonallinsulatorsasper
requirements.

5.1TESTINGANDASSEMBLINGSECTION:
There are several tests to be carried out to check for the quality of the product. These
testsinclude:

5.2HYDRAULICPRESSURETEST:
In this a huge amount of pressure will be executed to the fixed insulators (disc) at an
orderof180+/20kg/cm2forinsulatorsrangingfrom70KNto210KNandoforder200
+/20kg/cm2for320KNdiscinsulators.

5.3THERMALTEST:
The insulators, which are successful in the hydraulic pressure test, are subjected to
thermaltesting.Inthistestingtheinsulatoraredippedinhotwaterat90degreeCelsius.
Then within 60 seconds it has to removed from the hot water and has to placed in the
coldwaterwhichishavingatemperaturearound20degreeCelsius.Thistestisdoneto
see its withstanding capacity for fluctuation in temperature. If the insulator fails to
withstandthefluctuationintemperature,smallcrackswillappear.

5.4MALLETTEST:
In this testing, the insulators which have gone thermal testing are beaten using nylon
hammerof1.5kgsonthetopandthesideoftheinsulator.Ifthereisanysmallcrack,it
willberevealedandthusarerejected.

5.5ELECTRICALTEST:
Insulator is subjected to routine electrical testing at 70 KV to 80 KV for 4 minutes, 1
minuteforhighfrequencypowertestand3minutesforhighvoltagepowertest.Ifitfails
inthetest,itpuncturesandthusrejected.
Thesetestsaredonebeforeassembling.Thentheunitsgoforassemblingwhere
special, crock, cap, pin are placed using cement and is fed to steam dryer for initial
setting and then finally goes into hot water for 3 days and 1 day to steam. This final
product again goes for electric resting at 150 KV and the successful insulators are sent
for dispatch after packing. To do all these works are artisans separately for assembling
andtesting,abovethemistheseniorengineerandabovethemisseniormanager.

5.6.PACKING&DISPATCH:
Inthissectionthepackingofhollowbushingtakeplace.Theinsulatorisbindinbetween
jackofwood.Finallyitissendtodispatchunitforthepurposeofcustomer.

6.CERALINDEPARTMENT

Figure6.1:Ceralinfittedinpipe

Ceralin is having major presence in coal fired thermal power stations, Cement sector &
Steel Sector. Major customers list includes NTPC, DVC, Jindal, Tata Power, Nalco,
Hindaco,HZL,TorrentPower,StateElectricityBoardsfortheirPowerStations,SAILand
Cementcompanies.
An inherent part of any processing plant, big or small its material handling
systems.Becauseofcontinuoususage,thesesystemsaresubjectedtoalargeamount
ofwearandtear.Twofactorsaffectingthisareabrasionanderosionduetomaterialflow.

6.1NEEDOFCERALIN:
Ceralin a total solution against wear in steam generating units {boilers} and associated
pulverizesandotherauxiliaries,highaluminaceramicmaterialcanbeusedforprotection
ofcomponentsagainstwearduetoabrasionanderosion.
Coal is one of the main sources of fuel used in power generation. Coal fired
boilers adopt the method of pulverising raw coal in pulverisers or mills, conveying the
pulverised coalair mixture from the pulverisers to the boiler burner for producing and
utilising steam to generate power. Fine coal particles at high velocities cause failure in
many components in the pulverisers and the coal piping system of the boiler. Ceramic
lining is provided to the components to extend the life thereby reducing downtime. Its
superiorwearresistance,chemicallyinertandhighthermalstabilitycharacteristicsmake
CERALINsuitableforawiderangeofapplications:
PowerSector:WearpronecomponentsofBowl/TubeMill,FuelPiping.
SteelSector:SinterPlants,RotaryKiln,CokeOven
CementSector:Cement&RawMillschutes&AirSeparators
CoalSector:SlurryPipes,Chutes&Launders.
To combat the various wear prone areas in Coal fired Thermal Power Stations,
Coal
Sector, Steel Industry, Cement Industry and others similar applications, BHEL has
indigenouslydevelopedHighAluminaCeramicWearResistantmaterialsinitsR&D.
ComponentsfittedwithCERALINareusedalloverIndiawithaprovenperformance
The Ceramic Business Unit (CBU) of BHEL, is a Strategic Business Unit for
Ceramics and Systems.This business unit deals with Hightension Insulators, Ceramic
Wear Resistant liners, Industrial Ceramic Products and associated Systems. CBU is
headquarteredatBangaloreandissupportedby:
ManufacturingunitswithStateoftheArttechnologyforceramicproducts,
processesandapplicationsat:
ElectroporcelainsDivision(EPD),Bangalore
InsulatorPlant(IP),Jagdishpur
AdvancedResearchandDevelopmentfacilitiesforCeramicproducts,processes
and
Applicationsat:
CeramicTechnologicalInstitute(CTI),Bangalore(ADivisionofCorporateResearch
&Development,Hyderabad)

6.2PHYSICALPROPERTIES:
VolumeofMateriallostincubiccentimeterspertonofash
6.2.1TESTCONDITIONS:
ParticleVelocity
Erodent
PeriodofTest
AngleofImpingement

50m/sec
Ashconcentrationof0.25kg/Nm3
60min
450
Table6.1:Testcondition

Figure6.2:comparisonofceralinwithothermaterial

6.3OPERATINGCONDITIONS:
Incoalfiredsteamgeneratingunitsthenormaloperatingconditionsare:
Flowmedium
Particlesize

Pulverisedcoalmixture
70%lessthan75microns
15%75to90microns
15%90to150microns

Coalconcentration

0.935to1.545kg/Nm3

Ashcontent

50%Maximum

Flowvelocity

30mtr/Sec.Maximum

Pressure

0.5kg/cm2

Temperature

300oCMax

Table6.2:operatingconditionofceralin
The components are designed to meet the operating parameters and life expectancy
considerations.Iftheoperatingconditionisnotaslikeabovethentheceralinwillnotgiveits
bestperformance.

6.4PROCESSFLOWDIAGRAM
BallMill
SprayDrier
POWDE
RawMaterialWeighment&LoadingInSlipHouse(Ceralin)
Scrap
Assembly/Lining
FinishedProduct

R Dispatch
Loading/Firing
MetallicCasings
TilePressings
HTK

Figure6.3:Blockdiagramofmanufacturingofceralin

6.5MANUFACTURINGPROCESS:
Alumina which is the main constituent of ceralin, mixed with other additives in the
specified proportion i.e. 85% alumina, 10% clay and 5% manganese in ball mills. The
resulting slurry is mixed with organic binders i.e. PVA in a planetary mixer, after
dewatering and drying through spray dryer, it is granulated and this mixer is then
compactedthroughahydraulicpressintotherequiredshapeoftileandsinterinmodern
PLC controlled kiln i.e. in HTK or NUTEC BICKLEY up to 1520 degree centigrade.
Dependinguponthenatureofapplication,thesetilesarefixedtothebasemetalbyusing
cement.
Averagedaysrequiredforproductionis15days.Inordertoreducethepollution
control they have produced ceramic honeycomb substrates, the heart of a catalytic
converterforautomobilesforclearemission.Ceramichoneycombsarethinwalled,multi
chamberedcellularstructuresformedintomonolithbyexpression.Theyarecharacterized
ashavinglargesurfaceareas,excellentthermalshockresistance,highstrengthandlight
weight. Such design and properties make honeycomb substrates ideal for catalytic
reaction.
Inacatalyzedhoneycombsubstratesarecreatedinametalcarandfittedinthe
exhauststreamofasautomobile.Exhaustgasespassintotheconverterandthroughthe
multi channeled substrates where they make contract with the catalyst coated walls as
they interact with the catalyst, the harmful gases such as carbon monoxide,
HydrocarbonsandNitrousoxidearechemicallychangedintolesstoxiccompoundssuch
ascarbondioxide,Nitrogenandwatervapor.

6.5.1BALLMILL:
Inballmillthecrushingofrawmaterialtakeplace.Therawmaterialismixedwithwater
crushedout.Theoutputofballmillisslip.

Figure6.4:Ballmill

6.5.2SPRAYDRIER:
Inspraydriertheslipisconvertedintopowderform.Forthisfirstofalltheslipismoved
against the fire flame. The slip comes from upper side of drier and the elevated from
lowerside.Atjunctionofslipandflametheslipbecomedryduehightemperature.Sowe
gotthepowderofslurry.

Figure6.5:Spraydrier

6.5.3HYDRAULICPRESS:
SpraydriedpowderisthencompactedinHydraulicPressestoformtiles.Thesetilesarethen
fired in a high temperature kilns at around 15601600oC to get required wear resistant
characteristics.CeralintilesassemblytothecasingisdonebyusingMortar,Siliconeadhesives
orWeldontiles.

6.6KILNSECTION:
Kiln is the refractory lined structure where ceramic articles are fired to develop various
properties like mechanical strength, electrical properties, translucency, chemical
inertnessetc.Firingbyburnerscanbedoneintwoways,eithersidefiringorendfiring.
Thefuelusedmaybeoilorgas.

6.6.1TYPEOFKILNS:
Therearetwotypesofkilns

ContinuousKiln(OTK)
ShuttleKiln(SK

6.6.2CONTINUOUSKILN:
It runs continuously and is desired for mass production of ceramic articles to cater
continuousdemand.Insuchkilns,articlesarechargedatoneendanddischargedatthe
oppositeend.Apartfromfiring,coolingisalsodoneinsidethekilnitself.Oncestopped,it
takes considerable time to generate required atmosphere for firing. For example, tunnel
kiln.

6.6.3SHUTTLEKILNS:
It runs intermittently, when required. Unlike continuous kiln, it has only one door.
Charging&dischargingaredonethroughthesamedoor.Inthistypeofkiln,articlesare
loaded and the door is closed.After firing, the kiln is stopped. On subsequent cooling,
articlesareunloaded.FiringofgreeninsulatorsBushingsarecarriedoutinthisKiln.

6.6.4TUNNELKILN:
Itisacontinuoustypeofkilnhavingacapacityof20MT/day.Itwascommissionedway
back in 1983. Mostly, disc insulators are fired here.. Its total length is 120m and is
dividedintothreefollowingzonesasbelow:
PREHEATINGZONE
34.55METERS
HOTZONE
36.25METERS
COOLINGZONE
49.20METERS
Table6.3:Descriptionofheatingzoneintunnelkiln

6.6.5SALIENTFEATURESOFTUNNELKILN(IP):
TOTAL
LENGTH
OF
THE
KILN
WIDTH
OF
CAR
SETTING
HEIGHT
OF
CAR
SETTING
LENGTH
OF
PREHEATING
ZONE
LENGTH OF HEATING ZONE

LENGTH
OF
COOLING

120MTS
1415MM
1810MM
34.55MTS
36.25MTS
49.20MTS

ZONE
NOS.OFCARINPREHEATING
NO.OFCARINHOTZONE
NO.OFCARSINCOOLINGZONE
LENGTHOFTHEWAGON
NO.OFCARINOXI.ZONE
NO.OFCARINRED.ZONE
NO.OFCARINNEU.ZONE
TOTALNOS.OFCARSINKILN

17CARS
18CARS
23CARS
2006MM
07
10
01
58CARS

Table6.3:Descriptionoftunnelkiln
C1=80,C2=340,C3=470,C4=670,C5=750,C6=875,C7=1000,
C8 =1050, C9=980, C10=1050, C11=1150, C12 =1225, C13=1250, C
14=1225,C15=1120,C16=1000,C17=880,C18=620,C19=400,C20=70
B3/4=875,B5/6=930,B7/8=940,B9/10=890,B13/14=990,B15/16=1060
B17/18=1140,B19/20=1180,B21/22=1220,B23/24=1285

6.6.7 CROWN POSITION IN RESPECT OF BURNERS (IN

HOTZONE)
C6=B1/2,C7=B3/4&5/6,C8=B7/8&9/10,C9=B11/12,C10=B13/14&15/16,
C11=B17/18&19/20,C12=B21/22,C13=B23/24

6.6.8SALIENTFEATURESOFKILNS(IP):
SALIENTFEATURESOF
KILNS(IP)

OTK

SHUTTLE

NO.OFKILN
TOTALLENGTHOFTHE
KILN
WIDTHOF
KILN
HEIGHTOFCARAT
ARCH
HEIGHTOFKILNAT
CORNER
LOADINGSYSTEM
PRODUCTS

01
120

01
7200MM

1575MM

6100MM

2900MM

5000MM

2700MM

3270MM

SixDeck
DISCUP
TO210KN

KILNCYCLE

58Minutes/
Car
93%
08Hr

4to8deck
SOLIDCORE&HOLLOW
BUSSINGUPTO33
KV
120to150Hr

%KILNRECOVERY
LOADING/
UNLOADING
FUELCONSUMPTION
TEMPERATURECYCLE
SOAKING
OXIDATION
REDUCTION
COOLING

WAITINGTIMEOFGREEN

380L/TON
01Hr
07Hr
10Hr
22Hr

16Hrs

32TO40Hr
7000L./CYCLE

01TO04
hr
47TO52Hrs
18TO25Hrs
55TO60Hrs

72Hrs

Maxloadingtothekiln
20TON/DAY
72Hrs
POWERRCONSUMPTION 1000Unit/Shift
4600Unit/Cycle
Table6.4:Salientfeaturesofkilns(ip):
There is frequency of charging of wagon is 58 minutes.All the data are monitoring by a
digitalmonitoringsysteminkilncontrolroom.

6.7OPERATIONOFTUNNELKILN:
6.7.1CHECKINGOFTHERMOCOUPLE:
6.7.2OBJETIVE:
Thermocouples are used to know the temperature of the medium in the kiln at different
position.Thethermocouplewhichareusinginthekilnathightemperaturewillbespoiled
after some period. Therefore it is necessary to check them to understand the exact
temperatureinthekiln.

6.7.3TIMEOFCHECKING:
1. Thermocouple where the temperature (t=1200 0r more) should be checked regularly
onceinthreemonths.

2.Where(1100):Checkedonein6months.
3.Where(t<1100):Checksonceinoneyear.
6.7.4CHECKINGMETHOD:

I. Fixthestandardnewthermocoupleatcrowncoupleno.15i.e.inthecooling
zoneofOTK,becausethereisnotmuchvariationoftemp.withtime.

II.Nowrecordthetemp.Forafewminutesfirstandthenreplacethecouplewith
newonewhichwehavetocheckandrecordforafewminutes.

III. Now find out the difference of temperature on the chart. Similarly all the
thermocouplecheckedatthesamepositionandrecords.
IV. Now difference of the standard couple with checking couple indicate on the
chart.

IF:
1.Coupleindicatesmorethan10Cthencoupleshouldbeusedafterreveringthejoint.
2.Coupleareshowingmorethan20octhenshouldnotbeusedanyplace.

NOTE:Recordershouldalsobecheckedonceinayearbythemillvoltmeter.
6.7.5ORIFICEMETERFOROTKBURNERS:
1. Orifice meter should be fixed to the each burner to improve the adjustment of air
consumption.
2.Itisusedtoadjustthediameteroftheairnozzle.

6.8PREHEATINGZONETEMPERATUREINOTK:
To avoid the Baku defect in the article due to low temp. in the preheating zone and at
the same time to save gas consumption, the standard temp. in the preheating zone
shouldbemaintain.
Bottom temp. of the wagon has lower temp. as compared to middle and top
portions. Therefore, when thick article is loaded in the bottom portion then it might be
developBakudefectinthearticles.Recirculationfansareusedtomixthegasesattop
andbottominpreheatingzoneandhencereducethetemperaturedifferenceb/wthetop
andbottom.Actuallythesefanssucktheheatfromheatingzoneandexhaustinthepre
heatingzonebeforeexhausttoenvironment.

NOTE:
Standard temperature might be change according to the change of the body before get
exhaustthroughexhaustfan.

6.6.1TEMPERATUREOFOXIDISINGZONE:
Temperatureofoxidizingzoneshouldbefixeddependingonthefollowingfactors.
1.Thicknessofthearticles.
2.Finenessofthegrainsofthebodymass.
3.Materialcomponentsofthebodymass.
4.Amountofloadedarticles.
5.Methodofloading
6.Scheduledofthewagoncharging.
Consideringtheabovefactors,heatcurveoftheoxidizingzoneisdecidedeconomically.

6.9ACTIONSHOULDBETAKENINORDERTOMAINTAIN
THE:
6.9.1BURNERSTEMPERATURESAREASBELOW:
1.Checkingoftestpieces(sinteringtest).
2.CheckingofbendingpositionthroughOTK.

6.9.2TEMPERATUREOFREDUCINGZONE:
The standard temp. in reducing zone should be set within the specified range. these
temperatures should be maintain to get good reducing effect in the body before melting
theglazeandtogetgoodheateffectbeforereachingthehighesttemperature.

NOTE:1.
Adjustment of the temp. should be adjusting by a gas. Gas consumption should not be
changedfrequently.

NOTE:2.
To avoid the discolor defect due to oxidizing flame partly, the flame condition should be
checkedatpeepholeregularly.

NOTE:3.
Thetemperatureatanypairofburnersshouldbethesame.

6.9.3BURNERADJUSTMENTB/WOXIDIZINGZONEAND
REDUSINGZONE:

At the reducing firing method in the tunnel kiln, this operation should be done very
carefullybecausewrongoperationofthisburnercausesbukudefects.

1.Thereducingflamecomingoutfromreducingfiringzoneshouldnotbeenteredinthe
oxidizingzonehencemustbecutbytheairsuppliedbytheburnersB9andB10.

2. The top burner should supply more than double the volume of air the bottom burner
supply because it is necessary to make the flame flow down by the pressure of top
burnertoavoidtheBukudefectduetolessO2attop.
3.Atthepeephole7and8,ifpossiblethereshouldbenoflame,ifnot,verylittleflame
shouldbeallowed.

6.9.4IMPORTANT:
Tilloxidizing,thereshouldbenoflameifthereislittleflamethenflamecolorshouldbe
bluishasinthiszonevolumeoftheairrequiredismore(air:gasvolumeratiois
20:1).
Tillreducing,flamecolorshouldbeyellowasinthiszonevolumeoftheairrequiredis
less(air:gasvolumeratiois10:1).
Compositionofairandgasshouldbesuchthatthereshouldnotbeaccessgasinthe
flameotherwisesmokewillcome.

6.10CONTROLOFSANDSEALSAND:
Sand in the sandseal should be maintain to the correct level because it is used to
prevent the hot gases flowing to the under car.Always constant check should be made
toseethatcorrectlevelofsandismaintainedinsandseal.
Ifmoresandisfedthensandwilloverflowandthiswayliftsthewagonandthewagon
mayderail.
Iflowlevelismaintainthenhotgasesmaypasstotheundercarandcausedamage
totheballbearingsofthecarwheels.
OR
Cooling air from under car pass to the kiln and cause oxidizing at bottom row of the
wagonandthearticlewillbediscoloredaccordingtothepressurekilnandundercar.

NOTE:
Thesizeofthequartzsandgrainsforsandsealshouldbeb/w3mmto1.2mm.

6.10.1COCONTININREDUCINGFLAME:
ThemaintenanceofsuitableCOcontainisveryimportantinthereducingflamebecause
ifCOcontainisnotmaintainedthenfollowingdefectsinthearticleswillbehappens.
Bodybubbleduetoinsufficientreducingreaction.
Glazebubbleduetopresenceofmuchfreecarbon.

6.11METHODOFMEASUREMENT:
6.11.1COANALYSER:
It measures the percentage of CO contained in the reducing flame in the reducing zone
through peep holes. In OTK there are two positions where it must be checked, first
position is at the starting of the reducing zone and second is at last stage of reducing
zone.
If%ofCOvalueislessthanthestandardvaluethengasshouldbeincreased.
If%ofCOvalueisgreaterthanthestandardvaluethengasshouldbedecreased.

6.11.2BUKUSAMPLEFOROTK:
Bukusamplesshouldbeloadedandfiredalonewitharticles.Bukudefectsisnotvisible
fromoutsidethesamplehenceitshouldbebrokenafterfiringandcheckedtounderstand
theconditionsofarticlesfired.

6.12HOWTOAVOID:
Thiscanbeavoidedbycompleteoxidationinpreheatingzoneandoxidizingzone.

6.12.1OPERATIONOFRELIEFPORTINOTK:
(A)RELIEFPORTBRICKS:
RP1&RP2, RP3&RP4, RP5&RP6 are to be closed completely by bricks.RP7&RP8 are
tobehalfopenedandairvolumeremovingfrominsideofthekilnwillbeadjustedbythe
changingofthegap.

(B)RELIEFPORTDRAFT:
The relief port draft checking at the waste heat duct (before fan) should be adjusted
11mmofwatertube.

(C)RELIEFPORTDOOR:
Thedoorshouldbeopen25mmusual.Butthiscanbeopenedupto50mmtoadjustthe
wasteheatfantemp.lessthan300oC.

6.12.2OPERATIONOFUNDERCARCOOLING:
Thisoperationisdoneby:
Maindamperofcooling.
Undercarexhaustfan.
Blowingandinducingdamperslocatedatthesidesofthekiln.
Pressureoftheundercarshouldbeadjustedaccordingtothekilnpressure.Specialcare
shouldbetakentoadjustthepressureatthebeginningandmiddleofthereducingzone
otherwisethecoolingairwillpasstothekilnthroughthesandsealandcausediscolorof

wagonatthebottomrows.

6.12.3OPERATIONOFTHEMAINDAMPER:
Volumeoftheairtoundercarisdonebytheadjustmentofmaindamper.
Pressureismaintainbytheadjustmentoftheundercarfan.
Damperadjustmentmaybemadeaccordingtothekilncondition.

NOTE:
Operation of the sides dampers are made according to the pressure and volume of air
requiredatthedifferentplaces.

6.12.4NEUTRAL:
MaintainrequiredtemperaturebyoperatingLOV.Dontoperatecombustionairflow.
Note:Thisisthestatewherearticlesgetmatured.

6.13 CAR SCHEDULE IN OTK DURING POWER FAILURE

TIME:
During power failure time when the plant is switched off there is every possibility of
variousdefectssuchas:
Buku
Jiwa
Discolor
Porosity
Hence in order to minimize the above trouble we have to adjust the car operation as
follows.

6.13.1IFPOWERFAILURETIMEISWITHIN5MINUTES:
Car schedule should be changed by adding the actual period of power failure time (only
foronecar).

6.13.2 IF POWER FAILURE TIME IS LESS THAN 10

MINUTES:
This will affect the article in reducing zone. Hence after resuming of the power the first
wagon should be pushed by adding actual power failure period plus 3 or 4 minutes and
thenextwagonshouldbepushedatstd.scheduledtimeplus3or4minutesandfrom3rd
wagonstd.timemaybefollowed.

6.13.3 IF POWER FAILURE TIME IS LESS THAN 15

MINUTES:
Thewagonpushingandneutralzonetemperatureadjustmentmaybefollowedasper10
minutes shut down time and the std. time of schedule may be done from 4th wagon
insteadof3rdwagon.

6.13.2 IF POWER FAILURE TIME IS LESS THAN 30

MINUTES:
Thewagonpushingandneutralzonetemp.adjustmentmaybefollowasper15minutes
shut down and the std. time of scheduled may be done from 5th wagon instead of 4th
wagon.

6.14SAGERCONECHECKING:
(a)OBJECTIVE:
Thisisusedinthekilnwagonstomaintainuniformfiringandalsotocheckthemaximum
temperatureofarticlefired.Itconsistsofdifferenttypesofcolorwithdifferentnumbersof
pyrometriccones,suchas10,11,and12.Highertheno.valuemeanshigherthebending
temperature of the cone. Hence we can say that at the same temperature the bending
positionsofthedifferentnumbersoftheconedefinitelywillbedifferent.

7.TYPESOFDEFECTSWHICHMAYOCCURDURING
FIRINGOFTHESELL:
BlackSpot
PinHole
Bukku
Discolor
Jeewa
ColorDefect
SandSpurting

7.1BLACKSPOT(IRONSPOT):
Itisalsoknownasironspotbecausethisaffectoccurredinsideoronthesurfaceofthe
sellonlyduetothepresenceofironparticles.

7.1.1REASONS:
itmayhappenedduetofollowingreasons

(a)DUETOSLIPHOUSE:
If the iron particles present in slurry (In slip house) not removed through
magnatoscreeningthenitappearedintothebodyandmakeaspotduringfiring.

(b)DUETOGLAZING:
Atthetimeofglazingwhensellsaresmoothenthroughironequipmentbeforeapplying
glazethensomeirongetenteredintothebodyandcauseaspotduringfiring.

(c)DUETOLOADING:
Wagonaremadeupofironmaterial,ifthereisanycrushinthewagonthenironparticles
maycomeonthesurfaceofthesellandmakeaspotduringfiring.

(d)DUETOOUTSIDEAIR:
Iron particles may come on the surface of the sell from outside and may cause black
spotduringfiring.

7.1.2AFFECT:
Thereisnoaffectoftheblackspotonbothelectricalandmechanicalstrengthofthesell.
Sellisrejectedonlyduetobadappearance.
7.2PINHOLE:(HAPPENEDINTHEPREHEATINGZONE):
Ithappenedinthepreheatingzonewhenentrapgasescomesoutthroughthesurfaceof
thesellbodyaftermeltingoftheglaze.Itformstinyholesonthesurfaceofthesell.It
mayalsobehappenedwhensomedustparticlesfoundonthesurfaceofthesellatthe
timeofglazingburnoutinpreheatingzone.

7.3 BUKKU: (HAPPENED IN THE OXIDIZING ZONE):

REASONSFORBUKUDEFECT:
It happened when organic sample present in the sell do not completely burns inside
thebody.Ithappenedalsowhenthegasescomingfromthebodydonotcompletely
escapefromthebody.
Ithappenedintheoxidizingzonewhen02valueissohighthatitcoolthesurfaceof
the sell such as surface becomes sintered and prevent to incoming gases to
overcometothebodyofthesell.
After outside surface of the insulator is sintered, these gases remain inside and
accordingtogaspressureinsulatorbulgesandgivethebukudefects.
Bukudefectwillarisesometimesduetolesstemperature(mainlyatbottom)anddue
tolessofO2gas(mainlyatthetopofthekiln).

7.4DISCOLOR:(HAPPENEDINTHEREDUCINGZONE):
Asellcomesunderthecategoryofdiscolorwhensomepartofthesellcouldnotgetthe
actual gray color i.e. body gets two different colors. It can be avoided by controlling the
gas composition. If CO is less then increased gas & if CO is more then decreased the
gas.
7.4.1REASONS:
DiscolorhappenedonlyduetoinsufficientCOvaluepresentinthereducingzone.
Considerthefollowingreducingzonereaction:
Fe2O3+CO=FeO+CO2
CO2+CO2=2CO
Fe2O3+CO=FeO+CO2
FromabovereactionitisclearthatiftherewillbelessvalueofCOthensomepartofthe
sell will be converted in the gray colored (FeO)completely but some part will not be
Completelyconverted.
SoifthereislessCOthenwemustbecontrolitonlybyincreasingthegasand
the environment of kiln in this zone should be Smokey. Percentage of CO should be
checked at the peep hole just starting of the reducing zone and at the last peep hole of
thiszone.PercentageofCOshouldbefoundb/w3%to9%.

7.5JEEWA:(HAPPENEDINTHEREDUCINGZONE):
If there is access of CO percentage in the reducing flame then kiln environment will be
highly smoking then the CO2 gas which is comes out during firing hardly to comes out
due to presence of CO and results is come in the form of jeewa on the surface of the
insulatorsell.Itcanbecontrolledonlybycontrollingi.e.reducingthevalueofgasinthe
flame.

7.6 COLOR DEFECT: (HAPPENED IN THE NEUTRAL

ZONE):
When sell reached to neutral zone then body of sell is sharp and gets maximum
temperature i.e. 1285 0c.if at this temperature there is some smoky environment i.e.
reddishflamethenbodygetsabsorbthecarbonparticleandproducedcolordefects.So,
topreventthecolordefectwehavetoeliminatetheCOatmosphereinthisregion.

7.7 SAND SPURTING :( HAPPENED B/W THE NEUTRAL

ZONE(C13)ANDC16REGION):
Itappearedattheheadofthesellwhenthermalexpansionofthebodyoftheselldoes
not match with the thermal expansion of the glaze in that region. Kiln temperature is
always sated as per standard value of thermal expansion of the body so if there is any
changehasoccurredinthecompositionofthebodyeitherduetoalkalioranyotherthing
thenitcomesintheformofthisdefect.
So to prevent this defect, if there is some change has occurred in the body
compositionthenweshouldalsohavetochangethekilntemperatureinthatregion.The
peaktemperaturecangoupto1280C.

8.FIRINGPROCESS:
Firingisactuallyverificationofinsulators,whichcausesthecrystalstobecombinedwith
oneanother.Inotherwords,firingcanbetermedasaprocesswherecompactedceramic
shapesareheatedtoatemperaturewhereusefulpropertieswillbedeveloped.

8.1REACTIONSDURINGFIRING:
8.1.1LOSSOFPHYSICALWATER:
Thephysicalwater/moisturecomesoffaswatervaporbetween100and200C.

8.1.2OXIDATION(200800C):
Here organic substances contained in the body are carbonized or combusted between
300and500C.Theorganicmatterthuscarbonizedissubjectedtooxidationfromabout
800Candsocalledsootremovaliscarriedout.

8.1.3DECOMPOSITION:
Somecompoundsandtheirdecompositiontemperaturesareasfollows
(a)HYDRATESDecomposebetween1001000CgivingoffH2O.
(b)CARBONATESDecomposebetween4001000CgivingoffCO2.
(c)SULPHATESDecomposebetween10001200CgivingoffSO2.

8.1.4QUARTZTRANSFORMATIONS:
Silicagoesthroughvariouspolymorphictransformationsonheatingmentionedasbelow
Below573CAlphaquartz
573867CBetaquartz
8671470CTridymite

8.1.5COOLING:
After maximum temperature is reached, the vitrified body is subjected to cooling at a
definedrate.
Thekeypointinthecoolingprocessistocoolglassinversionpointofthecristobalite
at about 573C. When cooled below 600C, beta quartz transforms abruptly back to
alphaquartzwithasuddenvolumechange.
So,slowcoolingbetween600500Cisoftenrequiredtopreventcracking.
Firing is the process where the insulators achieve the required end characteristics
ofElectroMechanical(EMS),Bending&HydraulicStrength.
Itencompasseschemical&physicalchangesintheinsulatorbodyaccompaniedby
alossofporosityandasubsequentincreaseofdensity.

9.FITTINGOFCERALININMETAL:

10.USESOFCERALIN:
Itssuperiorwearresistance,chemicallyinertandhighthermalstabilitycharacteristicsmake
CERALINsuitableforawiderangeofapplications:
PowerSector:WearpronecomponentsofBowl/TubeMill,FuelPiping.
SteelSector:SinterPlants,RotaryKiln,CokeOven
CementSector:Cement&RawMillschutes&AirSeparators
CoalSector:SlurryPipes,Chutes&Launders

11.CONCLUSION:
Intheagehighdeficiencyofenergywehavetousetheelectricalenergyinbestmanner.
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
electricalenergyaswellsafetyfromelectricalenergy.
Theinsulatorismadeofceramicandporcelain.InBHELINSULATORPLANT
JAGDISHPURdiscinsulator,hollowbushingandceralinisproduced.Theinsulatordisc
isunitofstringusedasstring.
Thebushingisahollowinsulator,allowingaconductortopassalongitscentre
and connect at both ends to other equipment. Bushings are often made of wetprocess
fired porcelain, and may be coated with a semiconducting glaze to assist in equalizing
theelectricalstressalongthelengthofthebushing.
CeralinismanufacturedusingCalcinedAluminaasarawmaterial.Spraydried
powderisthencompactedinHydraulicPressestoformtiles.Thesetilesarethenfiredin
a high temperature kilns at around 15601600oC to get required wear resistant
characteristics. Ceralin tiles assembly to the casing is done by using Mortar, Silicone
adhesivesorWeldontiles.
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4comments:
Tejtara December9,2011at11:41AM
Ganeshmal: Exhaust Systems, Exhaust Manufacturing, Palvariser Manufacturer in
India.

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AbHiShEkvErMa February19,2012at6:53PM
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