Submitted in the requirement partial fulfillment

for the award of certificate of summer training

AT

Bharat Heavy Electricals Limited

INSULATOR PLANT
Jagdishpur (UP)

Under the supervision of :- Submitted by :-

Akhilesh Kumar Shivendra Kumar Mishra

Engineer (WEX) B.Tech (EN)

Bharat Heavy Electricals Limited SRMSCET

Jagdishpur, Sultanpur (UP) Bareilly

 ACKNOWLEDGMENT

I am very much thankful to the concerning officers and staff

of BHEL IP Jagdishpur for their valuable guidance and
advice , esp. to Mr. Akhilesh Kumar (Engineer/WEX) Without
their help, I would never have completed my training. I am
also thankful to “Executive-HR” for allowing me for this
training.

Shivendra kumar mishra

B.Tech (EN)

SRMSCET

BAREILLY(U.P.)
 CERTIFICATE

This is to certify that SHIVENDRA KUMAR

MISHRA a student of 3rd year B.tech(EN) of
SRMSCET BAREILLY has completed summer
training i.e. from 01/07/2015 to 31/07/2015 under my
guidance in BHEL(Insulator-Plant) Jagdishpur
Sultanpur.

I wish his grand success in future.

Akhilesh Kumar

Engineer(WEX)
Bharat Heavy
Electricals Limited
Jagdishpur,
Sultanpur (U.P.)
 CONTENT
1. Introduction to BHEL

2. Inroduction to BHEL IP Jagdishpur

3. Production Process Insulators and

Ceralin

4. BHEL IP WEX Department Functions

 Introduction

BHEL is the largest engineering and manufacturing enterprise in India in the

energy –related/ infrastructure sector, today. BHEL was established more than 50
years ago, ushering in the indigenous Heavy Electrical Equipment in India – a
dream that has been more than realized with a well – recognized track record of
performance. The company has been earning profits continuously since 1971-72
and paying dividends since 1976-77.

BHEL manufactures over 180 products under 30 major product groups and
caters to core sector of the Indian economy viz., Power Generation and
transmission, Industry, Transportation, Telecommunication, Renewable Energy
etc. The wide network of BHEL’s 14 manufacturing divisions, 4 power sector
regional centers, over 100 project sites, 8 service centers and 18 regional offices,
enables the company to promptly serve its customers and provide them with
suitable products, system and services- efficiently and at competitive prices. The
high level of quality and reliability of its products is due to the emphasis on
design, engineering and manufacturing to international standards by acquiring
and adapting some of the best technologies from leading companies in the word,
together with technologies developed in its own R&D centers. 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. The plan focuses on the capacity and capability enhancement
that will leverage the company’s effort in its core area of power, supported by
industry, transportation, transmission, exports and spares and services
businesses.

The vision of our BHEL is:

A world- class Engineering Enterprise Committed to Enhancing

Stakeholder value.

The company is striving to give shape to its aspirations and fulfill the
expectations of the country to become a global player.

The greatest strength of BHEL is its highly skilled and committed 44,500
employees. Every employee is given an equal opportunity to develop himself and
grow in his career. Continuous training and retraining, career planning, a positive
work culture and participate style of management – all these have engendered
development of a committed and motivated workforce setting new benchmarks in
terms of productivity, quality and responsiveness.

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, Captive and Industrial users. Supplied over 2,25,000 MVA transformer
capacity and other equipment operating in Transmission & Distribution network
up to 400 kV (AC & DC).

Supplied over 25,000 Motors with Drive Control System to Power projects,
Petrochemicals, Refineries, Steel, Aluminum, Fertilizer, Cement plants etc.
Supplied Traction electric and AC/DC locos to power over 12,000 kms Railway
network. Supplied over one million Valves to Power Plants and other Industries.

The mission of our BHEL is:

To be an Indian Multinational Engineering Enterprise providing Total
Business Solution through Quality products, System and Services in the
fields of Energy, Industry, Transportation, Infrastructure and other potential
areas.

BHEL INSULATOR PLANT, JAGDISHPUR

‘A UNIT OF BHEL’

Insulator Plant, Jagdishpur was inaugurated on 3rd March,1984 by then

Prime Minister of India Late Smt. Indira Gandhi , as 11 th manufacturing unit of
BHEL in Sultanpur District, 78 Kms. Away from Lucknow on Lucknow-Sultanpur
high-way. 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 diversified to the production of Industrial Ceramics
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 Electroporcelain Division, Bangalore and Insulator Plant Jagdishpur
got a technologically established and commercialised product .

For increasing the production of ceralin BHEL Insulator Plant installed a

modern Car Bell type High Temperature Kiln in the March 2009. This HTK has
firing capacity of 4 to 5 ton of products.

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 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 ISO 9001 certification in 1994, ISO
14001 and OHSAS 18001 certifications in 2002 for its well established
systematic production systems, standards, environmental management and
safety management.

In addition of these BHEL IP 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.

OBJECTIVES AND GOALS OF INSULATOR PLANT

1. Appropriately Integrate Manufacturing with Technology development and

further technology development with marketing.
2. Thrust on Export Marketing.
3. To maximize the Business in Ceramics Area by Business Development ,
Engineering and Technology Management (Technology
acquisition/Technology development/ Job to job tie up etc.).
4. To ensure earning on capital employed through efficient and effective use
of resources and enhance stake-holders interests.
5. To produce quality products in the field of Ceramics and attain & sustain a
good market share in Ceramic Industry of India.

PRODUCT RANGE:- .

DISC INSULATORS:

Products: Porcelain Insulators for 300 KN, HVAC, 160 KN HVDC, Post and
Pin, Fog and Anti Fog varieties for transmission lines. Insulators for
33 KV & 11 KV. 420 KN disc insulators has been developed and will
 be the product of next year. Hollow bushings are the main new
product of Insulator plant.

Customers: PGCIL, NTPC, NHPC, State Electricity Boards, Power Line

Construction Contractors & Export Customers.

CERALIN BENDS

Cerelin Bends of different specifications as required by the customers.

Customers: NTPC Limited and Other Power Generation companies.

2. Production:

Production department has following sections:

(a) Slip House: In slip - house the raw material are loaded per composition into

"ball-mills". In ball -mills 'river -pebble' are put as grinding -media. When ball

-mill is operated the grinding media and raw material produced the file paste

called 'slip'. This slip is the input for the 'filter- presses to produce the 'cake'. This

cake is output of slip -house and serves as input for manufacturing /Jiggering.

(b) Jiggering (Manufacturing): - The input for Jiggering station is cake

produced by slip -house. The cake are fed into 'pug-mill', 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 (chain-

dryer). After drying these shells are taken out of modes and send for finishing.

(c) Finishing &TD: - The unfinished shells are finished on MCBL (Multi Purpose

Vertical Lathe Machine). These finished articles are loaded onto racks fed into

"Tunnel -Dryer" or MDC. The output of the dryer is totally dried insulator or shell.

(d) Glazing: - The dried insulator shells are finished for minute tracks serration

the accepted articles are glazed on glazing machines with required thickness of

glaze.

(e) Kiln: - It works on oxidation - reduction process. The glazed articles are

loaded into refractory wagons and put into firing. Through OTK (oil tunnel kiln).

The gap between the loadings of two wagons is 50 to 60 minutes depending

upon the product composition. The fired and loaded shell are inspected for the

defects and on the basis of their merit accepted /rejected.

(f) Assembly & Testing: - The accepted fired shells .are tested for their

mechanical strength for loading hydraulically .The hydraulic accepted shells are

tested for thermal shock endurance .The O.K. shells are spread with 'Bituminous
Paint' on the head and the recess portion accommodate MCI (malleable cast

iron) cap/pin. The painted shells are assembled and cured insulators are put

under routine mechanical and electrical testing. A sample of insulator is tested

and put under destructive test .The tested accepted insulator are packed and

stored on specified vans.

(g) E&D (Engg. and Development): - This department provides the required

technical input /damages to a planning and procurement department. This also

works hands with commercial for tendering.

Flow chart for insulator production is as follows:

(h) Ceralin: - Ceralin stands for ceramic lining. The metallic bends, pipes, orifices

and other equipment of power plant are subjected to heavy temperature and

erosion due to abrasive materiel .To avoid this untimely failure of the component

lining of abrasive resistance materiel like high Alumina ceramic product is done.

At IP, Jagdishpur, components are lined with the ceramic product to avoid the

erosion.
Production Flow Chart for Ceralin:

Raw Material Weighment & Ball

Loading In Slip House (Ceralin) Mill Spray
Drier PO
W
D
E
Scrap
R

Loading / Firing

HTK Tile Pressings

Metallic Casings

Assembly / Lining

Finished Product

Dispatch
Main functions of the WEX department:

1. Break Down Maintenance: A state of M/C or equipment when it cannot

perform its desired function.

Breakdown Maintenance procedure:

The intimation of breakdown of the equipment is given by the user

department in “BREAKDOWN - MAINTENANCE REQUISITION” slip.The
requisition indicates the shop / section, description / name of the m/c
or equipment, nature of trouble, date and time of reporting the
breakdown. The intimation is also received by telephone and verbal
communication and followed up with the written requisition as above.
The intimation of breakdown is further entered in the log book “SHOP
BREAKDOWN LOG BOOK”.

The section-in-charge / section supervisor deputes the artisans to

attend the breakdown. On diagnosing the fault and analyzing the
reason the artisan attends to the breakdown by repairing or rectifying
the equipment. Spares / consumables as and when required are also
replaced / replenished. The technical / managerial support from
supervisor and or executive-in-charge as and when required for
diagnosis / analysis of the fault is also rendered.

- After repairs by the authorized person the user department and

intimation of handing over, the user / production department
representative checks the equipment & takes over the equipment
by confirming its restoration, date and time.

- The entries in the “SHOP BREAKDOWN LOG BOOK” is updated with

details of person attending the breakdown, nature of trouble,
spares consumed if any, handing over time etc.

- Daily break down report is fed in wex server (Break down 08-09)
and is analyzed.

List of equipment under breakdown or preventive maintenance

inclusive of carried over is prepared daily in “MAINTENANCE STATUS
REPORT” on computer by Area-in-charge. This status is communicated
by company wide e-mail to the concerned for monitoring on day to day
basis. A copy of the format for “MAINTENANCE STATUS REPORT” is
placed at Annexure-3 of this document.

2. Preventive Maintenance
In the plant there are many critical machines. To upkeep these machineries
maintenance department does Preventive Maintenance. The frequency of Preventive
Maintenance activities is fixed by Maintenance department and scheduling of
maintenance is done in co-operation with user departments, so that failures /
breakdowns can be minimized.

Preventive Maintenance procedure:

1. A List of critical equipments identified for carrying out scheduled

preventive maintenance. An annual programme for the preventive
maintenance is drawn at the beginning of the financial year.
2. The preventive maintenance schedule for these identified critical
equipments is drawn out.
3. The schedule of preventive maintenance is given to user
department. Further the user department is informed of the
equipment due for preventive maintenance one week in advance
through an “INTIMATION FOR PREVENTIVE MAINTENANCE”. This
intimation is not sent for the equipment under the control and
operated by WEX.
4. The preventive maintenance is carried out as per the pre-defined
check sheets. The check sheet is broadly classified under
“MECHANICAL” and “ELECTRICAL”. The machine is run on no load /
load as the case may be after carrying out the preventive
maintenance. The equipment is then handed over to user
department with due verification / confirmation.
5. In the event of user department not able to spare the machine for
preventive maintenance or WEX is unable to carry out the
preventive maintenance as per schedule, the reasons for delay and
re-scheduling of the preventive maintenance is recorded in the
annual preventive maintenance programme. By mutual consultation
the user and WEX decide upon the re-scheduled preventive
maintenance program and is carried out accordingly.

3. Calibration:

The calibration of instruments, gauges, measuring equipment etc.,

used in the manufacturing process of Insulators & Ceralin and other
allied activities like inspection, testing and maintenance are calibrated
in the in-house facility. The activity of Calibration is detailed under
‘Procedure for Calibration”.

4. Analysis of repeated Breakdowns:

The repeated breakdowns observed are analyzed, investigated and the

results of investigation are recorded. These identified corrective
actions are then implemented in the respective areas & monitored to
ensure its effectiveness through the Breakdown Analysis.

5. Condition Monitoring:

In plant, the condition of the machineries is regularly monitored and recorded by

Maintenance Department along with user departments. If any abnormality is
seen in any machines / parts, then required maintenance is carried out by
Maintenance Department. This type of maintenance is called as condition
monitoring.

Example of condition monitoring: {Condition Monitoring of Roto pump}

 Maintenance person record the noise level of bearing of roto pump

 Abnormal noise recorded
 Intimation was given to the production to release the roto pump
 After releasing, whole pump is dismantled and conditioned /
bearing changed.
 The roto pump was again assembled
 Trial run was taken.

6. Retrofitting:

Implementing new technology in old machinery is called as retrofitting. If the

performance of any machine is not satisfactory, then maintenance department
study the machine and identify the parts due to which, performance is decreased.
Then replacement of those parts with improved technology parts is done by
Maintenance Department itself or by sub-contracting.

Example of retrofitting: {Introduction of Planetary Gear Box in Ball Mill}

 Existing open geared ball mill was studied

 The retrofitting job, to be done, is designed (Vendor Catalogue was
referred)
  Specification of the planetary drive was prepared (Vendor Catalogue was
referred)
 Budgetary offers were taken from vendors
 Approval was taken of the budgetary offer & project was sanctioned
 Indent was prepared
 After procurement, installation of the planetary gear was done.
 Trial Run was taken.
 Improvements were observed and recorded.

7. Purchase Indenting:

For maintenance of machineries WEX Department needs spares/components/

parts/machineries. For purchasing these items purchase indent is prepared by
maintenance department and send it to the MM department for procurement of material.
This is the responsibility of WEX planning to make available all material at right time and
right quality and quantity. Inventory management of WEX department is taken care by
WEX planning.

8. Subcontracting of Works:

There are two types of sub-contracting

 Type I – Subcontracting of material-Components offload to

manufacturer or party.

 Type II – Subcontracting of Job-Labours contract (For

welding/fabrication etc.)-Consumables for this type of works
are supplied by BHEL.

9. Installation (Project Works)

The Works Engineering & Services department carries out the activity of
indenting, evaluation of offers, assisting in procurement, inspection / testing and
co-coordinating the installation activity of the new equipment / plant. The
installation of the equipment including erection & commissioning of the
equipment / plant may be carried out by the supplier of equipment as a
part of the purchase contract or through sub-vendors / sub-contractors. On
successful completion of the installation activity the “COMMISSIONING
REPORT” for the equipment is issued.