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Submitted in the requirement partial fulfillmentfor the award of certificate of summer training

AT

Bharat Heavy Electricals LimitedINSULATOR PLANT

Jagdishpur (UP)

Under the supervision of :- Submitted by :-

Gaurav Pandey Amar Prem Engineer (Manufacturing/Production) B.Tech (P.I.E)Bharat Heavy Electricals Limited Motilal Nehru National Jagdishpur, Sultanpur (UP) Institute of Technology

Allahabad Uttar Pradesh

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This to certify that Amar Prem student of B.Tech in Production & Industrial Engineering (4th sem) from Motilal Nehru National Institute of Technology 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.

( Gaurav Pandey )Engineer/Production Bharat Heavy Electricals Limited Jagdishpur, Sultanpur Uttar Pradesh

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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.

Amar Prem B.Tech (P.I.E) Motilal Nehru National Institute of Technology

Allahabad Uttar Pradesh

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CONTENTS1. An Introduction to BHEL IP Jagdishpur2. Insulators3. Power Distribution Plan4. Calibration Lab5. Ceramic Lab6. Boiler7. Manufacturing Process8. Manufacturing Of Insulators

a) Storageb) Slip Housec) Jiggering Unitd) Finishing Unite) Glazing Unitf) Firing unitg) Assembly Sectionh) Testing Sectioni) Despatch Section

9. Testing Of Insulatorsa) Routine Testb) Acceptance Testc) Type Test

10.Manufacture of Ceralin11.Evaluation Criteria & its Impact12.Environmental Policy Of BHEL13.Conclusion

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1)BHEL Jagdishpur – An Introduction

Jagdishpur unit of BHEL is the leading manufacturer of high tension porcelain insulators and distribution insulators like Bobbin, Shakle, Guy/Stay/Strain, Pin, Cap and pin type Post insulators in the country. The plant is equipped with highly sophisticated plant and machinery. This division also offers wear resistance high alumina ceramic lining materials for power, steel, cement and mining industries as well as a wide range of industrial ceramics.

The product portfolio can be divided into three categories:- LT type insulators Disk type insulators Ceralins

(a) LT type insulators These can be divided into four categories. They are:-

Pin type ( 10 KN. With creepage distance of 230/280/320 mm) Guy/Stay/Strain type( 53/89/110 KN with creepage distance of

42/52/65/72 mm) Shakle (11.5/15/16 KN. With creepage distance of 63/70/75 mm) Post type.

(b) Disk type insulators According to codes, they are divided into:-

Code

Strength(KN)

01 160 (CD-280 mm)02 70/90/12003 4506 120(CD-280 mm)08 21011 12013 12014 70/90/12015 70/90/120/16017 70/90/120

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(C) Ceraline:

Under ceramic line products or Ceralins it manufactures blends, cones, ventury vanes, O’Collars, multiple discharge valves, multiple outlets, fuel inlet elbows and other applications. Flyash tiles are also produced as per customer requirements.

Major Customers:

Major customers of BHEL IP Jagdishpur are1) NTPC2) Power Grid Corporation of India Ltd.3) State Electricity Boards4) R.P. Goenka group of industries5) Export to Middle East and African countries

The total plant capacity is 6000 CMT (Excluding the weight of metal parts)

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INSULATORS

The insulators for overhead lines provide insulation to the power conductors from ground. The insulators are connected to cross arms of the supporting structures of the power conductors and the power conductors pass through a clamp of the insulators. The insulators are mainly made of either glazed porcelain or toughened glass. The materials used for porcelain are silica 20%, feldspar 30% and clay 50%. The porcelain should be ivory white, sound and free from defects. It should be vitrified because the presence of air lowers the dielectric strength of porcelain. It is therefore desirable that the porcelain to be used for insulators should be air free and impervious to entrance of liquids and gases .The dielectric strength of porcelain should be 15 to 17 KV for every 1/10th inch of thickness. Normally it is difficult to manufacture homogeneous porcelain, and therefore for a particular operating voltage, two, three or more piece-construction is adopted in which each piece is glazed separately and then they are cemented together. Porcelain is mechanically strong, less affected by temperature and has minimum leakage problem. Toughened glass is also sometimes used for insulators because it has higher dielectric strength (35 KV for1/10 th inch thicknesses) which makes it possible for single piece construction, whatever be the operating voltage. As glass is transparent, the flaws like trapping of air can be detected. It has lowered co-efficient of thermal expansion. It has a disadvantage that moisture condenses very easily on its surface, limiting its use to about 33KV.

It is not desirable to allow porcelain and metal pieces to come together. So cement is used between them. It is seen that cement does not cause fracture by expansion or contraction.

There are three types of insulators used for overhead lines. They are:-

Pin type Suspension type Strain type

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i) Pin type Pin type insulators are normally used up to 33kv. In any case it is not

desirable to use them beyond 50 V as the cost of insulation becomes too high.

ii)Suspension type

Suspension type insulators, in addition to being economical as compared to pin type for voltage more than 33KV have the following further advantages:

1) Each insulator is designed for 11KV and hence for any operating voltage a string of insulators can be used.

2) In case of failure of one of the units of string, only that particular unit needs replacement rather the whole string.

3) The operating voltage of existing transmission can be increased by adding suitable number of disks.

iii) Strain Type Strain insulators are placed in horizontal plane rather the vertical planeas is done in case of suspension. These are used to take the tension of conductors at line terminals, angle towers, road crossings and junction of overhead lines with cables. For low voltages of order 11KV, the shackle insulators are used.

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Power Distribution Plan /(D.G.Supply)

Slip HouseTotal 4 No. Of 5 Ton Ball Mill / In place of one 5 Ton Ball Mill ,any 2 Ton Ball Mill, Two Nos. All Filter Press and all other Accessories. Compressed Air for B.M. discharge

Manufacturing Three Pug Mill Three Automatic Jiggering Machine

Finishing & TD Total Process

Glaze Generally upto 10 PM. In case it is require compressed air supply with one

compressor

TK & Shuttle Normal Operation for 24 hours.

A & T Total Operation (Exclusion –Chilling unit of TCT)

Ceralin Spray Drier One Press 70 T / 250 T HTK Normal Operation Ball Mill operation normal

Services Pump house:- Only one pump at any point of time. Siverage pump:- normal operation (It possible use 15 HP motor only in night) Boiler:- Normal operation Compressor :- 1 Nos. in night shift ( on requirement )

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CALIBRATION LAB

The calibration lab is used to calibrate different instruments used in the plant. Firstly the slave instruments are calibrated from the standard instruments and then they are used for the calibration of instruments used in plants time to time.

The instruments used in calibration lab are:-

Name Of Instruments

1. Vernier Caliper2. Depth Caliper3. STD Pressure gauge(40 KG/cm2)4. STD Pressure gauge(250 KG/cm2)5. STD Pressure gauge(700 KG/cm2)6. STD Vacuum Gauge(760 MMHG)7. Digital multimeter(750 Volt)8. Stop watch9. Thermocouple(R type)10. Thermocouple(K type)11. Thermocouple(B type)12. Mer. Thermometer13. Slip gaugeThere are other instruments also like IC TESTER which are used to test the functioning of IC.

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CERAMIC LAB

In Ceramic lab different tests are done on slip and the bar prepared from the plant to check the different contents of slip and physical properties of the insulator.Generally insulators are made from feldspar,quartz,clay etc. So the iron is injurious to the insulators.In this lab the physical & chemical testing are done to determine:- Physical

1. Particle size 2. Thermal Expansion3. Residue4. Sp. Gravity5. Viscosity6. pH

Chemical

1. Determination of SiO2

2. Determination of Al2O3

3. Determination of Fe2O3

4. Determination of CaO5. Determination of MgO6. Determination of K2O7. Determination of Na2O

Different processes like Spectrophotometry, Flame photometry, EDTA testing, Viscometer, thermocouple etc are used in this lab.Every day slip & different clay are taken from the slip house to determine different contamination in them and the moisture content in them.Then the report is prepared and send to the slip house so that they follow the instruction of the report.

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BOILER1. Evolve Material, Water and Oil balance for individual production operations and utility functions.2. Effluents from Ceralin, Boiler blow down and softner plant is let into open land, the same should be channelised to industrial drain.3. Most of the water line valves are leaking the same has to be repaired / replaced.4. Many places water valves are kept in open condition even if not required. Due diligence should be exercised to avoid unnecessary wastage.6. At jiggering machines transfer mechanism is not in use but the hydraulic system is running redundantly in all the three machines. 7. Water level controllers at pump house can be introduced8. Efficiency monitoring should be carried out for Boiler, Compressors and DGs 9. Lub-oil consumption of DG should be monitored and recorded.10. Steam, condensate and compressed air leakages in the distribution system to be avoided and constantly monitored.11. Monthly stack emission to be monitored and reported to UPSPCB for all the stack.16. Waste oil being hazardous - authorisation to be obtained for storage, handling and disposal of the same. Proper storage facility to be made and company wide oil balance to be drawn.

Manufacturing Process The various manufacturing units at BHEL IP Jagdishpur are as follows:

a) For manufacturing insulators i. Storageii. Slip Houseiii. Jiggering Unitiv. Finishing Unitv. Glazing Unitvi. Firing Unitvii. Assembly Unitviii. Testing Unitix. Dispatch Unit

b) For manufacturing of ceralinsi. Storageii. Slip House

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iii. Spray Drying unitiv. Pressure Shaping Unitv. Firing Chambervi. Fixing Unitvii. Dispatch Unit

MANUFACTURING OF INSULATORS

I) STORAGE The different raw materials for manufacture of insulators are stored in the identified bins. The raw materials are:-

1) Calcined Chaibasa clay2) Dolomite3) Manganese dioxide4) Chrome ore5) Calcite6) Talc7) Ellur Clay8) Than Clay9) Quartz for brown glaze10)Quartz11)Feldspar12)Bikaner clay13)Pyrophyllite14)Felcite15)Sericite16)Japan ball Clay

II) SLIP HOUSE

Slip house performs the following operations:

1. Weighing 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. Weighing should be rounded to nearest multiple of least count. Then the weighing card is attached to the lot. A sample data for preparation of suspension body slip in a 5 ton ball mill for the first charge are as follows:

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2. River-pebble charging: For initial charging of river pebble in the ball mill after reling, large, medium and small pebbles are collected as per standard samples and weighed as per specification No. PPSL: 0100 R-2 and pebbles are charged as per the quantity specified.

3. Preparation of first charge Bodyslip:

Weighed quantity of first charged raw materials are first charged into ballmill by attaching a cone to its hole from the charging hole on the platform. The pebbles are cleaned with water before charging. Then specified quantity of water is charged into the ball mill. The ballmill is run for the specified time and initial and final meter reading , time , ballmill number are also noted. Then a little quantity of first slip is collected for checking slip parameters. Generally charging takes 1-2 hrs and ballmill runs 14-16 hrs.

4. Preparation of second charge body slip

Weighed quantity of second charge is charged into the ballmill with required quantity of water after preparation of first charge bodyslip and the ballmill is run for specified time. After complete grinding the ballmill is stopped and sample is collected for checking slip parameters. Then the slip is discharged into mixing tanks and is agitated continuously.

5. Blunging return slip:

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 homogeneous slip. Then the slip is transferred to return storage tank by passing through Vibroscreen. The timely removal of foreign materials from the Vibroscreen should be ensured.

6. Preparation of cake: The filter press cloth should be free from folding and clay sticking before pressing operation and this must be ensured. The adequate power

Quartz 1053 kgFeldspar 603 kgPyrophylite 653 kgBikaner clay 387 kgFelcite 201 kgPebbles 157 kg ( due to the presence of

previously charged pebbles in the Ball Mill)

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pag pressure is applied and filter press is closed. The slip from the final tank is pumped into the press using plunger pump at 10-12 kg /sq. cm pressure to get cake of specified hardness as per process specification No. PS: 0100 R-Z. Then power pag pressure is released and cake is removed. Cake hardness is checked and cake is stored in specified area in stacks. Here the sliphouse work is completed.

III) JIGGERING UNIT

The cake from the sliphouse is fed into the plungmill. Plungmill makes dough of the cake and releases it in continuous cylindrical moulds. This continuous cylinder is cut into the required length by thread cutters. In some plungmills the cutting process is automatic. Then these moulds are shaped into required shapes by automatic jiggering machines. In case of pin insulators it is done manually by cutting machines.

IV) FINISHING UNIT: First the tools and the smoothing plates are checked. Before finishing, the article should be checked and and defective ones should be discarded. Then the article is placed on the rotating wheel and adequate layer of mass is removed without affecting die formation. Finally smoothening plate is used over entire finished portion to achieve smooth surface finish. The rotating wheel should be at rest while placing and lifting the article. Ambient humidity is maintained in the finishing area by special water sprayers in order to control specified finishing hardness of the article. Then the articles are placed on tunnel drier cars and the cars are led into temperature drying chambers. The stream pressure / waste heat is regulated and temperature of each zone of dryer is maintained as per process specification No. PPS: 0202 R-1. The racks are pushed into the drier at one end and released at the other end. Necessary corrective action is taken in case the moisture exceeds specified limits.

v) GLAZING UNIT Operations carried out:

1) CMC Solution preparation: Required quantity of water is taken in a bucket and then weighed quantity of CMC powder is added slowly to water with continuous stirring. The concentration of CMC solution should be as per specification no. PPS: 0203 R-0. The solution should be free from modules.

2) Sanding Glaze Preparations:

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Measured quantity of sanding glaze is mixed with CMC solution and the mix is agitated for 30 min.

3) Brown Glaze Preparation:

Brown Glaze from slip house is mixed with CMC solution as per process specification no. PPS:0203 R-0 for specified concentration. The glaze is agitated for 30 min before se.4) Glazing operation:

The visually inspected articles are loaded on the conveyor belt and article is again inspected for chipping, sharp edges etc. Such defects are removed by rubbing with sharp tools and steel wool. Sufficient compressed air jet is applied to the articles for removal of dust from the surface. Glaze is applied on the ‘g’ portion of the article with the help of brush of specified thickness. Then the articles are loaded on glazing machine’s spindle. The water spray nozzle is adjusted for proper spraying. The glaze nozzles are also adjusted in such a way that the glaze is poor on the entire surface of the article for a specified glaze thickness. The glaze article is removed from the machine spindle and is placed on auxiliary turn table. Glaze from ‘a’ portion of the article is removed with the help of sponging machine.

5) Sanding Operation: Sanding glaze is applied on the ‘f’ portion of the article with brush of suitable width and then sanding grog is poured. The article is then turned upside down and then placed on the wooden planks with sponge bedding. Then the article is placed on another hand wheel. Sanding glaze is now applied on ‘b’ portion of the article along with sanding grog. Then the articles are placed on the conveyor hangers.

6) Stamping Operation:

Stamping solution is prepared by mixing stamping powder with glycerin as per ratio given in process specification no. PPS: 0203 R-0. The solution is stirred till no nodes are left. A clean stamp as per rating is used to stamp the glaze articles. The articles are placed on the conveyor racks after stamping. At this point the job of glazing is completed.

vi) FIRING UNIT:

The firing work is done in the kiln. It is a continuous process. When one car is entering the kiln from the entrance door, one exits out through the exit door. The kiln temperature and the cycle time is maintained as per guide

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lines of E&D for controlling standard and routine rod thermal expansion at 250 and 650 deg C by making suitable adjustments of kiln operation parameters. When the wagon is discharged, the articles are unloaded for visual inspection.

vii) ASSEMBLY SECTION

The various operations performed during assembly are:

1. APPLICATION OF BITUMINOUS PAINT Bituminous paint and thinner are mixed in specific ratio as per specification no. PPS: 0400 R-0 for applying coating on cap, pin and shell surface which come in contact with cement mortar. This paint is applied on the pin by dip method and is allowed to dry before assembly. Paint is also applied on inside and outside grog portion of the cap by using a spray gun. The coated shells and caps are allowed to dry before assembly.

2. PREPARATION OF CEMENT MORTAR: Cement and quartz are mixed in cement mixer for 5 min. then the required quantity of water is added. Then the flow value of cement mortar is checked. If it is slightly less as specified in PPS: 0400 R-0 , then water is again added and mixed for 3-5 min. to bring it to required value.

3. ASSEMBLY OF INSULATORS: Cement mortar is poured inside the cap portion as well as the shell portion. A suitable cork is placed to insert the ballpin. The pin is placed manually. The shell is assembled in the cap and is pressed manually. The shell is twisted while pressing to eliminate entrapped air. The assembly quartz is sprinkled around the pin. The insulator is lifted and placed on the pre-curing chamber without disturbing the alignment of the components.4. ASSEMBLY OFINSULATORS: Specified temperature and humidity of curing chamber is ensured during initial curing. This is called temperature curing. The temperature is attained by blowing steam into chamber from the boiler house. Then the insulators are water cured for 24-36 hrs. in underground water tunnels at specified temperature. Finally the insulators are air cured for 24 hrs.

VIII) TESTING SECTION

The testing section is described in details in a later section

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IX) DISPATCH SECTION: The tested insulators are packed in seasoned mango wood crates with weather proof nature. They are then dispatched to customers according to work orders.

TESTING OF INSULATORS

Testing of insulators is of three types namely:

1. Routine test2. Acceptance test3. Type test.

Routine Test It consists of three sub tests. They are:

a) Physical verification test: After manufacture, the insulators are inspected visually for cracks and any visual physical defects. The defected ones are discarded.

b) Routine Mechanical test:

In this test 40 to 50% of rated mechanical load is applied on the insulators. The insulators incapable of bearing this load breakdown and are immediately discarded.

c) Routine electrical test:

The insulators are subjected to high voltage discharge (up to 80 KV) for 10 seconds followed by proper frequency voltage discharge (up to 80 KV) for 5 min. Then the insulators which are punctured re labeled with red stickers and others with green stickers. In case of faulty insulators the normal blue discharge arc is changed to yellow flame and insulator is immediately removed by stopping the machine.

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ACCEPTANCE TEST

Acceptance tests are conducted as per is-731 and iec-575. Acceptance tests are also called performance tests. These consist of 7 tests. They are:

a) Verification of standard dimensions:

The dimension of insulators are verified as per IS-731. They should confirm G.T.P. of drawing. Diameter, spacing, creepage distance also measured. Then eccentricity of insulators is checked by eccentricity testing machine. It needs venire height gauge and dial gauge for its measurements. It easures pin to cap spacing with venire gauge which should be according to specification.

b) Temperature cycle test(TCT)

This test is conducted to check the thermal stability of insulators. The entire trolley of insulators is dipped in hot bath for 15 minutes followed by dipping in cold bath for 15 minutes. This cycle is repeated three times. The difference in temperature between hot bath and cold bath should be higher than 70 deg C . Usually the temperature of hot bath is maintained at 85-90 Deg C with the help of water heaters. The temperature of cold bath is maintained at 15-20 Deg C with the help of water chillers.

c) Mechanical Performance Test (MPT): This test is conducted as per IEC-575 in thermo-mechanical chambers. In this test 60% of rated mechanical load which is tensile is applied to string of insulators. The load is 4-6 tons. The load is applied for 24 hrs. Hence it is called 24 hr mechanical performance test. This test is done by thermo mechanical performance testing machine.

d) Electro –Mechanical test: For electrical test 50-60% of rated voltage at power frequency is applied to the insulators. For mechanical test Universal Testing Machine (UTM) is used where 60 tonne tensile mechanical load is applied to the

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insulators to measure mechanical strength and breaking load of metal parts. Breaking load must be less than rated value.

e) Puncture test: This test is conducted to verify or note the voltage at which puncture of insulators occur. This is done in particular tank which contains transformer oil. First the insulator is dipped in the oil and then high voltage (AC) is applied to the insulators till puncture occurs and this voltage is noted. Puncture voltage should not be less than the specified voltage.

f) Porosity test: The non-porous property of insulators is checked by porosity test. For this purpose a solution of methyl spirit and a dye (1%) is prepared. Broken pieces of insulators are dropped in the solution and then pressure is applied by the compressors to the insulator loaded chamber for some hrs. Then broken samples are taken out and again broken to check porosity. Pressure in the chamber should not be less than 153 kg/sq cm.

g) Galvanizing test:

This test ensures proper coating of zinc on metal parts of insulators to avoid corrosion. It consists of 2 tests: one for mass of zinc on metal parts and other for uniformity of coating. Mass of zinc coating on the cap should not be less than 610 gm/sq-m. For this test we need hydrochloric acid. First pin or cap is weighed and then it is dipped in HCL for sometime. After reaction it is again weighed and the difference in weights give weight of zinc. Then taking standard area of zinc coating mass in gm/sq.-m is calculated. Similarly pin or cap is dipped in copper sulphate solution (of specific gravity 1.186 gm/cc at 18±2 Deg. C) for 1 min. to check uniformity of coating. This procedure is repeated 5 times. Uniform blue color indicates uniformity of coating.

TYPE TEST: Type test are conducted only once for not less than 2 insulators per batch. Some tests are conducted for both the insulators and some tests are conducted only once. All these tests should be conducted at specified atmospheric conditions, and then they must be corrected to 16 tests including 7 acceptance tests. Some of type tests are:

a) Power frequency with standard voltage testb) Dry flash over voltage testc) Wet flash over voltage test

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d) Pollution flash over voltage teste) Impulse flash over voltage testf) Sweeping surge testg) Steep wave front test

Impulse Voltage withstanding test

It is a type test conducted on insulators to check impulse withstands or flash over voltage. Impulse generator gives impulse for some time and voltage is noted. Impulse may be lightening or switching. For lightening impulse rise time is equal to 1.2 micro seconds 30%. Fall time is equal to 50 microseconds 20%. For switching impulse rise time is equal to 250 microseconds. Fall time is equal to 1250 microseconds.

MANUFACTURE OF CERALIN

1. STORAGE

Different raw materials are stored in identified bins. The raw materials are:

1) Alumina2) Quartz3) Tale4) Clay

2. SLIP HOUSE

Weight quantities of raw materials are charged into the ball mill. Also adequate quantity of water is added. The ball mill is run for specified time period. A slip is prepared. Then the ball mill is discharged into storage tanks which have continuous agitation facility.

3. SPRAY DRYING UNIT:

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The slip is pumped into the spray drying unit and is sprayed to the hot surface of the drier. The drier is heated by a burner which supplies heat by burning diesel. Due to this the slip is converted into powder form.

4. PRESSURE SHAPING UNIT

First the building material like PVM is added to the powdered material. Then the powdered material is pressed into desired shape by pressing it at high pressure in the specified dies. The required holes are also punched by punching machines on the slabs.

5. FIRING UNIT The bricks are placed on the kiln trolleys and are led into the kiln. The kiln used here is a high temperature kiln (1700 deg c). Then after firing the bricks are visually inspected for any broken edges and only non defective ones are supplied to the firing unit.

6. FIRING UNIT

The ceramic tiles are fixed to the inner surface of supplied cones or bends with the help of cementing materials. At places where very thin lining is required a silicon adhesive is used in place of cement. In this case the ceramic tiles are also fixed to the iron body of the bends or cones by welding iron butts through the hole in the ceramic tiles.

7. DISPATCH UNIT

The ceramic lined cones or bends are then dispatched to the respective customers according to the specifications.

EVALUATION CRITERIA & ITS IMPACT

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DEPT :CERALIN PRODUCTION ------------------------------------------------------------------------------------------------------------

ACTIVITY ASPECT IMPACT

1.RAW MATERIAL GENERATION OF AIR POLLUTION,TRANSPORTATION DUST & SPILLAGE DEPLETION OF

OF RAW MATERIAL NATURAL FORK LIFT EMISSION RESOURCES

2: .BALL MILLING2.1. WEIGHMENT GEN. OF DUST, AIR POLLUTION

SPILLAGE OF RM2.2BALL MILLING GEN. OF DUST & AIR POLLUTION

NOISE3.FILTER PRESSING SPILLAGE OF WATER DNR

4.CLOTH WASHING WATER WASTAGE DNR & WATER POLLUTION

5.BALL MILL LINING GEN. OF WASTE WATER POLLUTION

6.CAKE DRYING6.1 TRANSPORTATION SPILLAGE OF CAKE AIR POLLUTIONOF GREEN CAKE LAND

CONTAMINATION

7.POWDERING GEN. OF DUST AIR POLLUTION

8.BINDER SPILLAGE OF DNR, AIR POL. PREPARATION PVA,OIL

9.MIXING GEN. OF DUST AIR POLLUTION& SPILLAGE & DNR

10.COMPACTION SPILLAGE OF POWDER DNR

11.FIRING SPILLAGE OF HSD OIL, DNR & LAND LPG, CONTAMINATIONGEN. OF HEAT (SOLID WASTE)GEN. OF WASTE WATERGEN. OF WASTE REFRACTORIES

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12. CERALIN ASSEMBLY

1. TRANSPORTATION GEN. OF CEMENT DUST DNR & AIR OF CEMENT BAGS GEN. OF CEMENT BAGS POLLUTION (STORES TO SHOP) LAND

CONTAMINATION

2. CEMENT MIXING SPILLAGE OF MIX, DNR,LANDWATER CONTAMINATION

3. TILE CUTTING GEN. OF NOISE NOISE POL.

4. TILE GRINDING GEN. OF DUST AIR POLLUTION

5. WELDING GEN. OF FUMES, AIR POLLUTIONHEAT

6. GAS CUTTING GEN, OF FUMES AIR POLLUTION

7. PAINTING SPILLAGE OF PAINTS AIR POLLUTION& EMISSION OF VAPOUR

8. HANDLING CRANE GEN. OF NOISE NOISE POLLUTION

9. APPLYING GEN, OF VAPOURS AIR POLLUTION SILICONE ADHESIVE

10. TILE PACKING GEN. OF WASTED DNR & LAND PAPER,PLASTIC & CONTAMINATIONWOOD

11. REJECTED TILES GEN. OF SOLID LAND CONTAMINATION STORAGE WASTE

Environmental Policy of BHEL

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Environmental manualThe company has documented an Environmental Management System manual laying down procedures and instructions to ensure adequate environmental care throughout its operations and activities. The EMS Manual covers all the core elements of the standard.

Environmental policyTop Management has defined, documented, implemented and maintained an environmental policy. The Policy is signed by the General Manager and is appropriate to the nature , scale and environmental impacts of the company’s activities. The policy sets a framework for setting and reviewing the environmental objectives and targets. A system has also been established to ensure that the policy is communicated to all employees and is available to public and all interested parties. The Policy is displayed at prominent places, distributed to all employees through cards in Kannada, Hindi and English Languages. It is available to the public, contractors, suppliers and other interested parties. The awareness of the Policy amongst all concerned in the company and residential complex was found to be generally high.

Objectives and targetsThe management has set up objectives at organisational and Departmental levels. These are consistent with the policy based on significant aspects and legal requirements. For each objective the departmental targets have been set giving consideration to the technological options available, operational requirements and views of the interested parties. The objectives / targets are reviewed on regular basis at least once in six months.Some of the salient objectives having defined targets are as under :

1. To avoid generation of dust in the batch weighment area of Slip House.2. Prevention of long term land pollution on account of oil and grease leakage

during ball mill operation3. Prevention of water pollution due to oil leakage during membrane pump

operation4. Utilisation of polluted water from filter press operation for miscellaneous

production uses.5. Prevention of water pollution due to oil leakage during the filter press operation6. To reduce rejection of fired insulators for the year 2000-017. Reduce the dust level in dry finishing areas by installation of dust collection /

extraction equipment.8. Recycling of cooling water in Netzsch Pug Mill & Jiggering machines and Ceralin

– Bickley kiln sand seal.9. Replace asbestos material with non-asbestos material for various process

equipment use.10. To store hazardous waste at scrap yard scientifically by providing separate

storage bins impervious floor and covered roof.11. To collect the spills and leaks of electrolyte of batteries using stainless steel tray

and reuse of collected electrolyte for batteries maintenance12. To collect the oil leaking from lube oil filters in MS tray13. Providing storage and handling facilities for waste oil14. To eliminate the pollution caused by coal hearth during smithy operation by

changing over to LPG heating.15. To eliminate air pollution caused by diesel forklifts by changing over to LPG.