for project work

1. PROFILE OF THE COMPANY
A public limited company by the promoters, Mr. Padam J .challani chairman &CEO
and Mr. Prakash chand Jain, vice chairman, who have been in the business in Tamil
Nadu for more than two and half decades. SARAVANA GLOBAL ENERGY LIMITED
(formerly saravana insulators Limited) was established in the year 2003 by acquiring the total
assets of Mrs. Seshasayee industries Limited, a former reputed company, supplying High
voltage insulators, for transmission / distribution lines and railway electrification etc., The
promoters revamped, modernized and expanded and established the entire activities in
P.N.Kuppam, to produce High Alumina Porcelain Insulators required for power equipments,
Power Grid (PGCIL) having 1200 MT per month and the production operations were of Solid
Core, Post Insulators and Bushings for supplying up to 765kY to all Electricity Boards like,
TNEB, MSEB, APSEB, MPEB, KPTCIL, KSEB,
APTRANSCO etc. and others through insulators manufacturers.
THE PRODUCT RANGE COVERS THE FOLLOWING ITEMS.
~ Solid Core Long Rod Insulators up 765KY. Hollow Bushings, SF6 Circuit Breakers,
CTs/CYTs and lightning arrestors. 25KV Solid Core Insulators for Railway Electrification.
Solid core line post insulators
It is a well known fact that former Seshasayee Industries Limited ( SIL) had got a
high reputation with their consultancy and technical know-how from German, French&
Italian experts for manufacturing various Alumina Porcelain sophisticated under the guidance
of Mrs. Louis Locatelli who was a renowned European expert in the field.
Mr. Louis Locatelli trained many of the engineers and also established the high
strength Alumina body in India for manufacture of high strength solid core insulators and

2. high pressure bushings and the core engineers who are now with Saravana Global Energy
Limited in charge of production, testing, specification etc,. Were all people worked with Mr.
Louis Locatelli, Mr.Mario Audi and other leading ceramic experts and have also undergone
Training in European factories for manufacture of specialty insulators required by the power
industry. Besides putting up a sophisticated Plant with all imported machines and firing kilns,
Mr. Louis Locatelli helped the company at that to have a full fledged Extra High Voltage and
Mechanical testing lab which is also now modernized with updated instrumentation,
calibration of equipments etc.
So that the lab can be used for our own development and testing also for external
testing of electrical products to customers like Electricity Boards, Railways, PGCIL and
others. The Global power Research Institute (GPRI) (formerly Saravana EHV Lab)has been
accredited by National Accreditation Board for testing and calibration Laboratories(NABL)as
per S/ISO17025-requirements for Testing of Electrical and Mechanical tests up to 400K v for
Insulators, Porcelain and composite Insulators and Hardware.
It may be noted that the high voltage and extra high voltage product range is at par
with leading insulator manufacturers in India and abroad. There are about 850 employees
working in this company having requisite education, skill and experience in the
manufacturing of insulators. Lot of interest is being shown by leading switch gear
manufacturers in India and abroad ikeABB, Crompton Greaves, Areva, Siemens, L &
T,BHEL and others for supply of bushings, solid core Post insulators etc. (have their
confidence of the quality level and specification of the products which are being produced in
the factory
with background of the operating people and facilities and infrastructure created by
the Management to supply various products required-by utilities and power equipments
manufacturers).

3. MANUFACTURING PROCESS
The conversion of Raw Materials into a finished goods is proves as Known as manufacturing
process.
Raw Material
Ball Mill
Plunger
Filter Press
Pug Mill
PED
Shopping
Drying
Finishing
Glazing
Kiln
Cutting
Assembling
sting
Testing
Packing
Despatch
Raw Material:
There are different types of Raw Material
.:. HI Alumina
.:. HKC Clay
.:. TA Ball Clay
.:. Feldspar
.:. BGP Clay
.:. DM Clay
.:. NC II Clay
.:. Steatite

4. BALL MILL
Ball mill is a machine, which is used to grind or mix the raw material in a proper
composition. It rotates horizontally with a constant speed and it is also gear system. It takes 6
Hrs for grinding the raw material.
BLUNGER:
It is a tank which is present below the ground surface where scrap is poured and water
is added it. It resemble like a fan like structure which consist of blade. A fan rotates for
several hours to form the slip. The segmentation is settled in the blunger and only the slip is
transferred to the filter press.
FILTER PRESS:
Filter press is a machine which is used to remove the water from the slurry by
applying pressure with help of hydraulic system, and the pressure increased and the water
removed through the nylon cloth due to increased pressure. This operation goes nearly 3-4
hrs to bring a cake formation.
PUG MILL:
It is a fabrication machine which is used to bring the filter cake into desired shape
with the required dimension. The vacuum condition must be maintained inside the PUG mill
in order
to avoid breakage; air is converted from low pressure to high pressure. The unloaded cake is
rotated to become noodles like structure. Finally we get the desired shape.
DRIER (PED): PUG ELECTRIC
It is the process in drying section where the PUG gets dried by using electric supply
approximately 500 voltages is applied. Then it is allowed to drying for 40 hrs
(approximately) for evaporating moisture content by potential difference created in it. The
time. Taken for the process of drying varies for different shapes and sizes.

5. SHAPING:
There are two types of shaping system followed
A. Manual
B. CNC Program
A) Manual
It is used on individual person to can design the PUG with the help of temp plate.
B) CNC Program
It is systematic process and set to the program after work down the design on
automatically.
THERMIC FLUID HEATER:
After shaping, the PUG has to be taken to drying process and bring to required
moisture content of 0.5% (approximately) in it.
The temperature inside the drier must be increased day to day
FINISHING BOOTH
This section where the surface of the PUG has to be shined.
GLAZING AREA:
A. Dipping
B. Monogram
A.Dipping
Here, The PUG pieces are dipped in the suitable coloring agent (liquid state) which is
stored in large rectangular tray where the surface of the PUG gets required colour whichever
colour wants.
B.Monogram
It is the place where the stickers are pasted on the surface of the PUG.

6. The stickers giving the information about manufacturing date, company logo and serial
number.
KILN:
It is a systematic process. There are two types of kiln.
Shuttle Kiln
Tunnel Kiln
In SGEL it used on shuttle Kiln. It is used to heat on 3 days the designed pieces at a
very high temperature of above 1230° c to 1250° c. After 2 days attaining the maximum
temperature, the cooling has to be done. At the end of the cooling, the temperature is
maintained at room temperature 35° c to 45° c the time taken to complete the process be
varying for different material.
SORTING:
After Kiln process it will check insulator piece come to correct shape.
CUTTING:
Insulator unwanted top and bottom part can be cut and removed them.
ASSEMBLING:
It can assemble the metal parts are fixed with the help of cement like injection type at the top
and bottom part of the insulator.
TESTING:
It has five types of testing
Tensile testing
Bending testing
Hot water temperature testing
Cold water temperature testing
~ Curing chamber
A) Tensile testing

7. We can know how much length the ceramic material can able to expand.
B) Bending testing
It can withstand how much bending force acting on it.
C) Hot water temperature testing
It can with stand up to what extent of higher temperature.
D) Cold water temperature testing
It can with stand up to what extent of low temperature.
E) Curing chamber
It is a chamber into which the ceramics placed for particular period of Time with a
continuous spraying of cold water or stream on it on order to check whether any properties of
the materials can change.
PACKING:
After finishing the testing process. Finally the insulator is packed within the wooden box.
DISPATCH YARD:
After packing products are kept ready for dispatch.