Bharat Heavy Electricals Limited Ceramic Business Unit
Bharat Heavy Electricals Limited The Company Bharat Heavy Electricals Limited is the largest Engineering and Manufacturing Enterprise of its kind in India. It ranks amongst the leading manufacturers of power plant equipment in the world. BHEL has 14 manufacturing plants, 4 power sector regional centres, 8 service centres, 18 regional offices and over 150 project sites spread all over India and abroad. It offers a wide spectrum of products and services for core sectors like Power Generation, Transmission, Distribution, Industry, Transportation, Oil & Gas, Defence and Non-Conventional Energy Systems. Ceramic Business Unit The Ceramic Business Unit (CBU) of BHEL, is a Strategic Business Unit for Ceramics and Systems. This business unit deals with High Tension Insulators, Ceramic Wear Resistant liners, Industrial Ceramic Products and associated Systems. CBU is headquartered at Bangalore and is supported by: Manufacturing units with State of the Art technology for ceramic products and systems at Electroporcelains Division( EPD), Bangalore Insulator Plant (IP), Jagdishpur Advanced Research and Development facilities for Ceramic products, processes and applications at Ceramic Technological Institute (CTI), Bangalore ( A Division of Corporate Research & Development, Hyderabad) Products High Tension Insulators for Transmission and Distribution lines from 11 to 800 Hollow Insulators for Instrument and Power Transformers, Switchgear, Electro Static Precipitators, etc. Station Post Insulators for Bus bars, support and for Isolators from 11 to 400 Composite Insulators for Railway Traction and Transmission applications up to 400 Wear resistant materials for Thermal Power Plant applications, Steel, Coal Washeries, Cement, etc. Industrial Ceramic Products for various applications BHEL The Pioneer in Insulators BHEL pioneered the development of composite insulators in India in the year 1998 through in-house development efforts. Today its State of the Art facilities manufacture Polymer insulators that compare with the best in the world. BHEL make Composite insulators have superior design features that ensure reliability and excellent performance backed by years of expertise in the insulator business. Our Esteemed Customers Our Composite Insulators are approved and are in Service with the following customers: Research Development and Standards Organisation (RDSO) of Indian Railways Powergrid Corporation of India Ltd. NTPC Ltd. Tamilnadu State Electricity Board Nuclear Power Corporation of India Ltd. Gujarat Mining Development Corporation Ltd. AREVA T & D Maharashtra State Transmission Company Ltd.
The Manufacturing Shop Modern state-of-art manufacturing facility for production of Silicone composite insulators with complete manufacturing and testing facilities. The Process Crimping State of Art Microprocessor controlled Crimping machine with Acoustic Crack detection ensures uniform crimping without stress concentration Injection Moulding The Silicone housing is injection moulded over FRP rod in a fully automatic Microprocessor controlled Injection Moulding Machine. The housing is bonded securely over the entire length of the FRP rod The Materials Fiber Glass Rod Metal Fittings Silicon Rubber Raw materials (Silicon Rubber, Boron free ECR grade FRP Rod & SGI Castings/Steel Forged Metal Fittings) are sourced from reputed manufacturers after undergoing stringent quality checks.
Construction Features Acid Resistant Core rod (ECR Glass) Forged steel Metal Fitting - Galvanised Weather Sheds designs for pollutted conditions Interface Core to Housing- Thicknesss conforming to IEC Interface- Silicone Overlapping Metal Fitting Double sealing Silicone Housing Manufacturing features unique to BHEL Weather shed housing overlap at end fittings ensures no moisture penetration. Segment joining through Lap Jointing to ensure perfect sealing of joints Ultrasonic cleaning of end fittings after galvanizing to remove moisture, greasy matter and rust. Infrared curing of FRP rod to remove moisture Silicone dough procured from reputed manufacturer after complete technical evaluation No binders or fillers are added to dilute the properties of Silicone Metal fittings made of High quality forged steel / Spheroidal Graphite Iron castings.
Quality & Reliability BHEL s Composite insulators undergo rigorous design tests, type tests, routine tests and acceptance tests in conformance to IEC 61109 and IEC 62217. BHEL has facilities to carry out all the required tests for incoming materials such as Silicone, FRP rods and metal end fittings. Some of them are a) Rheological characteristics of Silicone compound to determine curing characteristics b) Specific gravity and shore hardness after curing of Silicone c) Tensile and tear strength of Silicone compound d) Die penetration, Water absorption, density, BD voltage tests on FRP rods e) Tensile, microstructure, galvanisation tests on metal end fittings. Rheology Tensile testing Die Penetration Test BHEL polymer insulators have successfully undergone stringent design tests in conformance to IEC 61109 Annexure C1, at world renowned laboratories at KEMA, Holland Hydrophobicity test BHEL Polymer insulators undergo various routine tests and acceptance tests in conformance to IEC standards as well as Customer specific test requirements 1. Routine Electrical test 2. Mechanical Strength test 3. Thermal Mechanical Performance Test BHEL insulators successfully undergone 5000 Hrs Accelerated Aging Test at KEMA, Holland as per IEC 62217
Advantages of Silicone based Composite Insulators Superior Handling of Mechanical Shock Loads hence convenient to handle, transport and erect. Low weight ( < 80 % of conventional porcelain) easy handling Resistance to Vandal Damage Superior Dielectric Strength High Power arc resistance due to high thermal Withstand ability Excellent Pollution Performance (Durable & Regenerative Hydrophobicity) Flame resistant Shatter resistance Aerofoil design offering minimum Wind Resistance Low Leakage current and Power loss due to its high surface resistivity Regenerative Hydrophobicity o Wide range of service Temperatures (from 50 C to o 100 C) Interchangeability can easily replace existing Porcelain insulators Better Aesthetics Silicone Composite Insulators Vs Porcelain Insulators Weight ratio Porcelain to Silicone Composite insulator for Railway Traction applications is 3:1 W e i g h t r a t i o between Porcelain I n s u l a t o r a n d composite long rod i n s u l a t o r s f o r t r a n s m i s s i o n applications is more than 10:1 making c o m p o s i t e insulators an ideal insulator for lines with limited right of way
Our Range of Composite Insulators LONG ROD TECHNICAL PARTICULARS OF COMPOSITE LONG ROD INSULATORS TONGUE & CLEVIS TYPE BALL & SOCKET TYPE Parameter 1. Shed Diameter (Big / Small) 2. Unit Spacing 3. Creepage Distance 4. Arcover Distance 5. Electro-Mechanical Min. Failing load 6. Coupling Designation 7. PF-WET Withstand Voltage 8. PF-DRY Withstand Voltage 9. DRY-Lightning Impulse Withstand Voltage 10. Visible Discharge Test Voltage 11. Weight of Unit Unit kn P kg 11 11 33 33 285 3 140 45 16 35 40 75 9 1.0 375 370 160 1 45 50 90 9 1.5 325 900 340 70/90 16 75 85 170 27 4.0 375 1110 360 1 85 95 170 27 4.5 1. Sketch is indicative only. 2. Specific creepage distance from 16 / to 40 / 3. Length ranges from 285 to 4080 4. Specified mechanical loads from a. 45 KN to 1 KN for 33 KV to 132 KV. b. 70 KN to 160 KN for 2 KV. c. 1 KN to 160 KN for 400 KV. 5. For specific requirement, contact: CBU / Marketing, Malleshwaram, Bangalore...560012
Our Range of Composite Insulators LONG ROD TECHNICAL PARTICULARS OF COMPOSITE LONG ROD INSULATORS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Parameter Shed Diameter (Big / Small) Unit Spacing Creepage Distance Arcover Distance Electro-Mechanical Min. Failing load Coupling Designation PF-WET Withstand Voltage PF-DRY Withstand Voltage DRY-Lightning Impulse Withstand Voltage Visible Discharge Test Voltage Weight of Unit Unit kn P kg 66 66 770 870 2250 2250 560 560 70/90 1 16 140 140 150 150 325 325 53 53 4.8 5.5 1 Sketch is indicative only. 2 BHEL Manufacture & supply a Specific creepage distance from 16/kv to 40/kv b Height ranges from 285 to4080 c Specified mehanical load require from 1KN to 160KN for 400KV. 45KN to 1KN for 33KV to 132KV. 70KN to 160KN for 2KV. 3. For specific requirement, contact: CBU / MARKETING, Malleshwaram, Bangalore...560012
Our Range of Composite Insulators LONG ROD TECHNICAL PARTICULARS OF COMPOSITE LONG ROD INSULATORS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Parameter Shed Diameter (Big/Small) Unit Spacing Creepage Distance Arcover Distance Electro-Mechanical Min. Failing load Coupling Designation PF-WET Withstand Voltage PF-DRY Withstand Voltage DRY-Lightning Impulse Withstand Voltage Visible Discharge Test Voltage Weight of Unit (approx.) Unit kn P kg 110 110 132 132 1460 3870 1175 70/90 16 185 0 450 88 6.0 1460 3870 1175 1 185 0 450 88 6.8 1450 4300 1210 70/90 16 275 325 650 105 7.5 1460 4300 1210 1 290 335 650 105 8.0 1. Sketch is indicative only. 2. Specific creepage distance from 16 / to 40 / 3. Length ranges from 285 to 4080 4. Specified mechanical loads from a. 45 KN to 1 KN for 33 KV to 132 KV. b. 70 KN to 160 KN for 2 KV. c. 1 KN to 160 KN for 400 KV. 5. For specific requirement, contact: CBU / Marketing, Malleshwaram, Bangalore...560012
Our Range of Composite Insulators LONG ROD TECHNICAL PARTICULARS OF COMPOSITE LONG ROD INSULATORS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Parameter Shed diameter (Big/small) Unit Spacing Creepage Distance Arcover Distance Electro-Mechanical Min. Failing load Coupling Designation PF-WET Withstand Voltage PF-DRY Withstand Voltage DRY-Lightning Impulse Withstand Voltage Visible Discharge Test Voltage Weight of unit (approx) Unit kn P Kg 2 2 400 400 2610 8000 2300 70/90 16 500 575 1080 154 11.5 2610 8000 2300 1 500 575 1080 154 12.2 3335 10500 3050 1 680 7 1550 305 18.5 3910 130 3400 160 680 7 1550 305 21 1. Sketch is indicative only. 2. Specific creepage distance from 16 / to 40 / 3. Length ranges from 285 to 4080 4. Specified mechanical loads from a. 45 KN to 1 KN for 33 KV to 132 KV. b. 70 KN to 160 KN for 2 KV. c. 1 KN to 160 KN for 400 KV. 5. For specific requirement, contact: CBU / Marketing, Malleshwaram, Bangalore...560012
Railway Traction for Standard and Polluted applications TECHNICAL PARTICULARS OF COMPOSITE RAILWAY TRACTION INSULATORS STAY ARM BRACKET 9-TONNE Parameter Unit Stayarm Insulator Bracket Insulator 9-tonne Insulator 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Shed Diameter Unit Spacing Creepage Distance Arcover Distance Bending Strength Electro-Mechanical Min. Failing load PF-WET Withstand Voltage (horizontally) PF-WET Withstand Voltage (vertically) DRY-Lightning Impulse Withstand Voltage positive DRY-Lightning Impulse Withstand Voltage negative Visible Discharge Test Voltage Weight of Unit (approx.) kgfm kgf P P kg 185/145 489 1050 390 0 7000 125 100 240 260 35 4.4 185/145 555 1050 390 0 7000 125 100 240 260 35 5.0 185/145 540 1050 390 210 11000 125 100 240 260 35 5.4 Sketch is indicative only.
Bharat Heavy Electricals Limited (A Government of India undertaking) Registered and Corporate Office BHEL House, Siri Fort, New Delhi - 110 049. Tel: 011-2600 1010 Fax: 011-2649 3021 www.bhel.com Efforts are constantly being made to improve the product design and hence the products supplied may differ in minor details from that given in the catalogue. For enquiries please contact: Bharat Heavy Electricals Limited (A Government of India Undertaking) Ceramic Business Unit Prof. C.N.R. Rao Circle, Opp. Indian Institute of Science Malleswaram, Bangalore-560 012 (India) Ph: 080-23442988, 22182247 Fax: 080-23560741, 23344231 www.bhelceramics.com