Bharat Heavy Electricals

Limited,Jagdishpur,Sultanpur(UP)

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 :Mr.Hamid Raza

Dubey
Senior Engineer
Bharat Heavy Electricals Limited
ElectricalEngineering
Jagdishpur,Sultanpur(UP)

Submitted by:Chandresh Dhar

B.Tech,3rd Year
NIT Manipur

CERTIFICATE
This to certify that Mr.CHANDRESH DHAR DUBEY ,student of
B.Tech in Electrical Engineering (7th sem) from NIT Manipur has completed
his summer training in Bharat Heavy Electricals Limited (Insulator Plant)
Jagdishpur from 01.06.2016 to 30.06.2016 .
During this period I found his to be very co-operative, sincere & hard
Working.
I Wish his good luck and success for all his future assignments.

(Hamid Raza)
Senior Engineer
Bharat Heavy Electricals Limited
Jagdishpur,Sultanpur(UP)

ACKNOWLEDGEMENT

I am very thankfull to all concerning officers and staff of BHEL,I.P. Jagdishpur

for their valuable guidance and advice without which I could not have
completed my summer training.

Chandresh Dhar Dubey

B.Tech,4rth Year
ElectricalEngineering
NIT Manipur

ABOUT THE COMPANY:

1964 :
Established Heavy Electricals (India) Limited
1972
:
In July the operation of all four plants were
integrated
1974
:
In January Heavy Electricals (India) Ltd.
Merged with BHEL.
BHEL is largest engineering manufacturing enterprises in
India in the energy related/ infrastructure sector today, BHEL
was established more than 50 Years ago, ushering in the
indigenous Heavy Electricals Equipment in India- a dream
that has been more than realized with a well- recognized
track record of performance. The company has been earning
profit continuously since 1971-72 and paying dividends since
1976-77.
2012
:
The Honble President of India, Shri Pranab
Mukharjee, presenting the National Energy Conservation
Award 2012 to Mr. B. Prasad Rao, Chief & Managing Director
(CMD), BHEL.
2014
:
BHEL bags India Today Best Maharatna PSU
Award for Global Presence & Innovation

Trophy conferring Maharatna status on BHEL

from Honble President of India in recognition
of companys consistent high performance.

Sh. R. Krishnan, Director (HR) BHEL was

conferred NIT-Trichys Distinguished Alumnus
Award by the former President of India,
Dr. A.P.J. Abdul Kalam as part of Golden
Jubilee celebrations of the Institute

CONTENTS
1. INTRODUCTION TO BHEL
2.BHEL INSULATOR PLANT, JAGDISHPUR
Power Distribution Plan
Calibration Lab
Ceramic Lab
Boiler
Manufacturing Process
Manufacturing Of Insulators
Storage
Slip House
Jiggering Unit
Finishing Unit
Glazing Unit
Firing unit
Assembly Section
Testing Section
Despatch Section
Testing Of Insulators
Routine Test

Acceptance Test
Type Test
Manufacture Of Ceralin
Evaluation Criteria & its Impact
Environmental Policy Of BHEL
Conclusion

1. INTRODUCTION TO BHEL
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 well-recognized track record of performance. Established in
the late 50s, Bharat Heavy Electrical Limited (BHEL) is, today, a name to
reckon with in the industrial world. It is the largest engineering and
manufacturing enterprise of its kind in India, and one of the leading
international companies in the power field. Established in the late 50s,
Bharat Heavy Electrical Limited (BHEL) is, today, a name to reckon with in
the industrial world. First It Was Incorporated In 1964 with 3 Plants Located
At (1)HYDERABAD
(2)TIRUCHY
(3)BANGALORE.
Second Generation Plants Were Setup In Mid 70s At
(1)JHANSI
(2)RANIPAT
(3)TIRUCHY

(4)BANGALORE
(5)HARIDWAR.
1.1 MANUFACTURING UNITS OF B.H.E.L
First generation units:
BHOPAL
: Heavy Electrical Plant
HARIDWAR
: Heavy Electrical Equipment Plant
HYDERABAD
: Heavy Electrical Equipment Plant
TIRUCHY
: High Pressure Boiler Plant Second generation
units:
JHANSI
: Transformer and Locomotives Plant
HARIDWAR
: Central Foundry and Forge Plant
TIRUCHY
: Seamless Steel Tube Plant Units through
acquition and merger:
BANGALORE
: Electronics division
and Electro porcelain division
New manufacture unit:
RANIPAT
: Boiler auxiliaries plants
JAGDISHPUR
: Insulator plants
RUDRAPUR
: Components and Fabrication Plants
BANGALORE
: Industrial system group
BHEL is growing concerns to meet the changing needs of the nation has
taken it beyond power into the total gamut of energy, industrial and
transportation BHEL is able to offer a total services in each of these fields. Its
manufacturing capability is supported R and S division at Hyderabad work
closely with research 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 over India &
abroad and with an export presence in more than 50 countries,
BHEL is truly Indias Industrial ambassador to the world. All major
Manufacturing, Erection and Service units of BHEL have been awarded ISO
9000 certification. 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 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 sectors of the Indian Economy viz., Power Generation &

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 largest engineer and manufacturing in the field of heavy
electrical in India and among the leading power equipments manufactures in
the world.
BHEL has presence in core sector like power, industry, transportation, oil and
gas, telecommunication, defense and non-convectional energy source from
concept of commissioning.
BHEL products and systems have been exported to over 52 countries
worldwide.
BHEL has continuously contributed dividends to the government.
BHEL also received Excellent rating for 9 years consequently memorandum
of undertaking targets with Government of India and has conferred the price
status of a Navarathna Company another major contribution of BHEL to the
nation is by the way of its involvement in the social development work. Such
as adoption of backward villages, buildings and running of schools, medical
centers providing self-employment facilities for windows, handicapped
persons etc. 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 .
During the financial year (2004-05), Bharat Heavy Electrical
Limited (BHEL) has achieved 110% of CEAs target of commissioning by
adding 3548 MW to the national grid. This was made possible because of the

advanced commissioning of a 500 MW unit (Rihand 3), not in the CEAs plan
for that period. With this the company has once again demonstrated its
capability and commitment to providing maximum value to its customers
significantly, 90% of coal-based sets added in the country during the year
were of BHEL make, while 80% of hydro MW addition and 79% of dieselbased MW addition was contributed by BHEL sets. Even during the current
fiscal, BHEL is fully geared up to add 30 coal, hydro, nuclear and gas-based
sets aggregating to 3712 MW to the countrys generating capacity. In
addition during this period, 73% of electric energy generated by utilities in
the country from coal, nuclear and hydro based units was contributed by
BHEL make sets, even though BHEL-sets constitute only 65% of the total
generating capacity.
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 record time of just 36 months and 10 days, nearly three months
ahead of schedule. 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 turnkey execution of thermal
power projects last year, by commissioning the 2x250 MW Tau Devi Lal
Thermal Power Station of Haryana Power Generation Corporation Limited in
just 34 months. Also a new benchmark was set with the commissioning of
both the units within a span of only 4 months. It is worth mentioning that
even one months advance commissioning of a 500 MW unit results in an
approximate saving of about Rs. 75 Crores to the utility. In order to cope with
the countrys ambitious target capacity addition in the 11th and 12th plan,
BHEL is gearing up to enhance its equipment manufacturing capacity from
present 10,000 MW
1.2.1 POWER GENERATION SYSTEMS:
to 15,000 MW annually by March, 2008. This should enable the company to
play a major role in power generating capacity addition program of the
country.

1.2 SYSTEM AND SERVICES:

1.2.1 POWER GENERATION SYSTEMS:
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 was approximately 64% of the installed capacity
in India in March 1993. Presently, BHEL has capacity to supply power
equipment equivalent to 7000 MW per year.
(A)THERMAL GENERATION: The unit sizes of utility stations in India range
from 30 MW to 500 MW BHEL has so for 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 technology has been acquired through 20 years of
collaboration/license agreement. Both these collaboration covered unit
ratings up to 1000 MW. Operating in an environment of high technology and
severe competition as BHEL does, the company has perform to stay abreast
with the technology leaders in the world. It is in recognition of such
imperatives that BHEL has technology tie-ups around the world for a variety
of power station auxiliaries as well.BHEL has a well chalked out programmed
to assimilate, adapt and modify such acquired technology to suit differing
economic, developmental, geographic & climatic requirement. The company
has also a full-fledged Research and Development Division which undertake
fundamental and applied research in power and related fields. Research; is
being carried out on non-conventional energy sources as well. Several of
these efforts such as those in the areas of fluidized Bed Combustion, Solar
and Wind Power have already resulted in commercial ventures.
(B) HYDRO GENERATION: BHEL has supplied Hydro Sets upto 165 MW
rating and 200 MW sets are under manufacture, BHEL has facilities to
manufacture and install sets of even higher rating as per specific customer
requirements. It also supplies turbines for low head mini and micro 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 various types and capacities tattling to about 12000 MW.
(C)NUCLEAR GENERATION: 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 power stations.
(D) GAS TURBINES BASED GENERATORS PLANTS: Today BHEL is fully
equipped to supply simple/confined cycle/cozen plants with various 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 Siemens AG, Germany. The agreement with GE,
USA covers rating from 4.6 MW (ISO). The Siemens agreement covers unit
rating from 130 MW to 200 MW. So far BHEL has Supplied more than 33 nos.
Has a turbine. All these turbines have been supplied from our Hyderabad
plant based on general electric, USA technology. BHEL has bagged orders for
two gas turbine based projects in Malaysia, commissioning schedule of 6- 10
months. The first

1.2.2 TRANSMISSION SYSTEMS:

project has already been commissioning in 6 months time. While the gas
turbines of GE/USA design are supplied from Hyderabad plant. With the
plants (i.e. Hyderabad and Hard war) are fully equipped with state of
manufacturing and testing facilities.
BHEL is fully equipped to supply waste heat recovery boilers from
their Tiruchirapalli plant. BHEL have an ongoing collaboration agreement
with M/S Henry volt, USA for the Waste Heat Recovery Boilers. BHEL is
supplying WHRSGS foe 6X30 MW gas turbines for Delhi electric supply
undertaking, and 817 MW Dadri Project of national thermal power
corporation limited besides those for other power stations.
-Turnkey power stations.
- Combined-cycle power plants.
- Cogeneration systems.
- Modernization and rehabilitation of power stations.
- Erection commissioning, operation and maintenance services.
- Spares management.
- Consultancy services.
In addition to equipment for generating of power, BHEL supplies a variety of
equipment for transmission and utilization of power. The company has also
undertaken a number of turnkey sub-station contracts for voltage rating up
to 400 kv class. Keeping with the KM long HVDC (High voltage direct current)
transmission line project line for reliable and efficient transmission of bulk
power.
BHEL has in house capability to supply most of the equipment like
power transformer current transformer, voltage transformers switches,
insulators etc., and also possesses in house modern testing facilities. Billions
of BHEL manufactured insulators of various ratings up to 160 KN are
satisfactory service in many countries namely Turkey, Egypt, Malaysia, Iran,
Iraq, USA Libya, Tanzania Dubai and course India.
- Sub-stations switchyards.
- HVDC transmission systems.
- Shunt and series compensation systems.
- Power system studies.
- Erection commissioning,
-operation and maintenance services.
- Consultancy services.
1.2.3 TRANSPORTATION SYSTEMS:
For over quarter of a century, BHEL has been supplying drives and control
for traction equipment mainly to the Indian Railway, which is the third largest

Railway network in the world. Today, 65% of the rolling stock in Indian
contains electric of BHEL make such as 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 -both diesels electric as well as A.C. Locos. The urban
transportation problem demands different solutions and BHELs contribution
extends to underground tube, light rail and battery powered road vehicles.
- Traction systems.
- Urban transportation systems.
- Erection commissioning, operation and maintenance services.
- Consultancy services.
1.2.4 INDUSTRIAL SYSTEMS:
The industry Sector of BHEL offers diverse items such as Transformers,
Switcher, Rectifiers, Insulators, Capacitors, Control Gear, Valves
Compressors, Pumps, Piping, Motors, Industrial turbines oilrigs and
semiconductor devices to meet the varying needs of industry.
- Industrial drives and control systems.
- Erection commissioning,
-operation and maintenance services.
- Spares management.
- Consultancy services.

1.3 SERVICES:
1.3.1 PROJECT ENGINEERING:
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 works relating to optimization of
cycle configuration selections of parameters and design of suitable system
for power stations with a total MW capacity of 30000 and is currently
involved in several turnkey project including stations having 500 MW unit
size.
1.3.2 CONSTRUCTIONS MANAGEMENT:
BHEL has a full-fledged 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.
1.3.3 SERVICE AFTER SALES:
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. BHEL has a separate

spare group response for insuring ready availability of essential spares to

Power stations.
1.3.4 PROJECTS MANAGEMENT: 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 activities that are necessary for the performance of the project right from
the conception stage until the contractual obligations are fully discharged.
BHEL offers a wide spectrum of products and services for core sectors like
power transmission industry, transportation, oil & gas telecommunication
etc, deseeds supply of non-conventional energy systems. It has also
embarked it to other areas including defence & aviation.

1.4 COMPANY OBJECTIVES

A dynamic organization is one which keeps its aim high adopts itself quickly
to the changing environment. So here we are in BHEL.
1.4.1 VALUES:
Strike adherence to commitments.
Foster learning, creativity and team work.
Ensure speed of response.
Respect for dignity and potential for individual.
Loyalty and pride in the company.
Zeal to excel and zest for change.
Integrity and fairness in all matters.
Most of them have been rephrased.
"Zest for change" has been added as change has been integral with success
and the rate at which change is needed is very high compared to earlier
period.

2. 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 11th
manufacturing unit of BHEL in Sultanpur District, 77 Kms. Away from
Lucknow on Lucknow-Sultanpur high-way. BHELs 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 BHELs Electro porcelain Division, Bangalore
and Insulator Plant Jagdishpur got a technologically established and
commercialized product.
For increasing the production of ceralin BHEL Insulator Plant installed a
modern Bell type High Temperature Kiln(NEUTEC BIKLEY) in the March 2009.
This HTK has firing capacity of 4 to 5 ton. 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 2009. This shows the dedication
of each individuals of unit for the quality of works and product. The insulator
plant BHEL, catering to electric power transmission business by way of
manufacture and supply of disc insulator. Presently the plant is geared to
produce 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
160-Kn.Stength ranging from normal to antifog type. The plant has till date
executed many prestigious export contracts and has supplied disc insulators
to Turkey, Malaysia, Trinidad & Tobago, Ghana, and Nigeria etc. 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 company has not only gone for diversification but also has taken
concrete measures for organizational and product improvement by ISO-9001
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 view to provide
strategic global market information for insulator exports. BHELS more than
40 years experience in the ceramic field ,blended with that of 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 18th months.
Insulator plant Jagdishpur has developed into
one of the Indias disc insulator manufacturing centers with the most
streamlined layout and modern technology.It6 has provisions to cope with
latest advances in the ceramic field.
2.1 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.

2.2 PRODUCT
RANGE:
Disc Insulators up to 210 kN strength for transmission lines up to 765 kV
AC, 500KV and 800kv HVDC Disc Insulators.
Hollow Bushings for 11kv and 33kv kV Systems.
Bus bar support for 11kv and 22kv line. Ceramic Liners (Ceralin) for
wear resistant applications.
2.3 MAJOR RIVALS OF BHEL INSULATOR PLANT, JAGDISHPUR:
v Jai shree insulators, kolkata (birla group)
v Ws insulators, kolkata (west bengal)
v Modern insulators, chennai
v Iec, kolkata (west bengal)
v Bathinda ceramics, punjab
v Hi-tech, khurja (u.p.)
v Power tech, khurja (u.p.)
2.4 MAJOR CUSTOMER OF BHEL IP JAGDISHPUR:

Jagdishpur insulator plant has some important customer which are state
electricity board, government organizations, public sector units and private
customer and Indian railways.
customer and Indian railways.
2.4.1 STATE ELECTRICITY BOARDS
v UPPCL
v MPSEB
v GEB
v PSEB
v KSEB
v KPTCL
v TNEB
v MSEB
2.4.2 PUBLIC SECTOR UNITS
v POWER GRID
v NTPC
v NHPC
v DVC
v NLC
v Government Organizations
v Govt. of Tripura
v Govt. of J&K
v Govt. of Mijoram
v Govt. of Manipur

2.3
JAGDISHPUR

BHEL PRODUCT PORTFOLIO,

The Product portfolio divided into three categories:

1. L T Type insulators
2. Disk Type Insulators
3. CERALINS
L T TYPE INSULATORS

a) Pin Type (10KN, with distance of 230/280/320mm)

b) Guy/Stay/Strain (53/89/110KN with distance of 42/52/65/72mm)

c) Post/Suspended Type

3.

PRODUCTION OF DISC NSULATORS