W.S Industries (India) Ltd..

ORIENTATION REPORT

BY, R.V.KRISHNA BHALAJI.. B.E (MECH)

INTRODUCTION: WSI was established in 1961 with a vision of creating an enduring benchmark in India for strategic excellence in electro-porcelains. The Goal: The continuing drive to synthesize material technology with manufacturing competence to develop innovative product solutions. W.S industries had head quarters in Chennai; its a leading player in the Indian insulation industries. Managing director is Mr. Narayan Sethuramon. Vizag plant is started by an investment of 140 Crores. WSI has major customers like Areva, ABB and Siemens. Major customers are European and US customers. 90 % of the goods are exported.

Products
Solid core insulators from 11kV to 420kV are manufactured at WSI. The cantilever strength ranges from 2KN to 20KN and the specific creep age from 16mm/kV to 40mm/kV. Hollow porcelain insulators for various applications ranging from transformer bushings from voltage range 11kV to 500kV are manufactured at WSI. INSULATORS FEATURES: Abrasion resistant Best for maintaining safety in electrical appliance Reliable for conductors

INSULATOR USAGE: Electrical appliance manufacturing industry Commercial and domestic sectors Transmission and distribution system for electricity

STEP BY STEP PROCESS

Raw material Mixing ball mill Blunger Screening Filter press Pre Pugging

SOLID CORE INSULATORS Pre Pugging storage Pugging Blank drying Turning Drying Glazing and sanding Firing Cutting Testing Assembling Mechanical testing Packaging

HOLLOW INSULATORS Pre- Pugging storage Pugging Blank drying Turning Drying Glazing and sanding Firing Grinding Shell testing Condition room for epoxy joint Beam test Assembling Testing Packaging

SLIP HOUSE
In this region five types of raw material are stored namely, Lilite Hymod KC ball clay Sanifill ball clay Feldspar MDS alumina

These five types of raw material are collected in separate conveyors to the skip hoist, from the skip hoist the raw materials are mixed at respective proportions and load it on ball mills. Five ball mills are there. In ball mill, the different raw materials are mixed with each other and grinded to fine pieces, pulverized to powder form. Running time of the ball mill is 4 hours. After four hours of grinding the output is feed to the tank of capacity 6.6 tones. Ball mill have the capacity of 5 tones. So the remaining 1.6 tones are filled with water. Blunger stirred it into a semisolid form. Then it goes to sieves, where the impurities or foreign materials are removed manually then it discharge into syntax tank. From the syntax tank the slurry is pumped to filtration process. In between, magnets separators are used to remove the iron contents in the slurry. Two Blunger are there. First one will produce fresh slurry from raw materials. And second blunger will make from the recycled or scrap. These two are mixing with a ratio of 24:76. That is 24 % of fresh slurry and 76 % of recycled slurry. Flow pumps are used to pump the slurry from tank to the filtration process. In filtration process 300 bar pressure is applied. It can able to produce 70 plates per press. Filtration process is used to remove moisture content of the slurry. After filtration process the solid piece of highly moisture clay is passed to the small extruders through a conveyor. In those small extruders, a cake like formation is made and keeps in a room to reduce the moisture content. In that room it will be for 24 hours and the moisture content will be reduce to 19.5%.

PUG MILL
A pug mill is a machine in which materials are simultaneously ground and mixed with a liquid. The cake shaped clay is feed into the extruders, in which a vacuum chamber and a sliced plate. It makes the clay to the formation of noodles it helps to remove the air holes in the cake. And in vacuum chamber the moisture is absorbed. Vacuum is maintained by vacuum pump. Extrusion process is carried out and blank is get as a result. Two extruders are there one is german made which produce hollow blanks. And other extruders are made in gujarath which produce solid core blanks. After the blank is extruded, the code number and identification numbers are punched in it. Then it processed to EDB, namely electrical block dryer. Blank is processed here because for machining purpose we need to have the material moisture content at below 18%. So now it will have 19.5%, to reduce the moisture content blank drying is made. At the two ends brass sheet is provided so that it helps to fix the electric point on both ends. In EBD the blank will be for 3 days and the electricity given to the blank is about 230V. Nearly 14 EBDs are there in which 1 -9 are automated and 10 -14 are manually controlled. 1 3 EBD having capacity about 66 blanks. 4 9 EBD having capacity about 90 blanks. 10 -14 EBD having capacity about 96 blanks.

CNC Turning
CNC - Computerized Numerical Controller. Vertical lathe is used for turning purpose. Turning refers to decrease the diameter depends on the profile. In computer the program is feed, it shows the stimulation of the process in the screen to check the result. Two types of codes used in CNC machine namely G-codes and M-codes. G-code means geometric codes; M-code means machine codes Few examples of G-codes and M-codes G01 linear interpolation G02, G03 clockwise and anti clock wise circular interpolation M07 coolant on M09 coolant off

In the plant totally 6 CNC machines are there. The blank is turned to the respective profile and using jigs and fixtures the machined blanks kept at the cars to dryer.

DRYING SYSTEM
Any moisture content in the blank may cause the piece to burst, while heating in the kilin. So in order to avoid that drying system is used. In this system the moisture content of the blank is reduce from 17.5% to 0.4%. Two types of drying system are used. Depends on the size of the clay piece the system varies. The insulator height up to 3 to 4 feet tunnel dryer is used. From more height CDS chamber drying system is used. In chamber drying system Max temperature is maintained at 120C. Time duration is about 7 8 hours. While in TDS tunnel Drying system, Min temperature will be 40C and the maximum temperature will be 110C. Two tunnel drying system are there. Tunnel one had a capacity of about 4 cars per day and its inlet temp: 60C ; Exit : 110C ; Tunnel two had a capacity of about 6 cars per day and its inlet temp : 70C ; Exit : 105C GLAZING Dried and quality passed wares ID finishing Transfer ware to glazing station Finishing of the ware Dust removing with air Water sponging Wax application on bottom footer Dipping in glaze Glue application Sand application Glaze eye spraying on sand area Glazing scraping at top footer Fevicol spraying on petticot Transferring ware to kilin loading area

SHUTTLE KILIN Shuttle kilin is the region where after that the insulator piece can be recovered or recycled if any damages persist. So quality department had more preference in those areas to minimize the losses. Shuttle kilin in nothing but an heating chamber. Two shuttle kilin are there. Fuel used for this is LPG and the Maximum temperature it achieved is 1205C. Two heat exchangers are there. Four blowers are used. Two are for primary purpose for sucks the air and exhaust the air. Secondary blowers used to spread the heat uniformly in the kilin. Approximately 8 hours of oxidation and 12 hours of reduction is carried out. Two shuttle kilin are there. First kilin had a capacity of 150 pieces. And the second kilin had a capacity of 175 pieces. CUTTING AND GRINDING In case of holding purpose additional clamping region is provided in the Insulator pieces. Those are not needed after the insulator attains its brittle structure. So the cutting and grinding section is doing this operation. Horizontal lathe is used for cutting purpose. Chambering is done on the edges for ease of assembly. Additionally Epoxy room is there. As per the customers requirement two insulators are joined together with chemical substance namely aradalite, hardener. These two substances should mix in the ratio of 10: 4. After joining, drying should be done for about 18 hours under normal temperature. If rainy or cloudy weather it should be dried for 24 hours.

TESTING & INSPECTION

Temperature testing, Di-Electrical testing, Pressure testing, Dimension testing, Cantilever testing, Beam testing.

Testing department will do a testing depend on customers requirements Depends on the application of the insulator the testing will be carried out.

TEMPERATURE CYCLE TESTING: In temperature cycle testing the insulator is treated in hot water of about one and half hours after that it is placed in cold water for one and half hours. It helps to predicts the insulator withstand capability to the climatic conditions. Due to sudden changing of temperature from hot to cold the material will expands and compressed. If the insulator is not good, cracks will form during this testing. Minute cracks will form which can be determine in Di-electric testing. Mallet test is carried out by beating with wooden piece on the insulator, by sound it produce defects are deductable. DI-ELECTRIC TESTING: In di- electric testing, electricity is passed over the outer diameter of the insulator through aluminum chain. Inside the insulator water is poured. High voltage is passed through the chain. If any cracks in the insulator the voltage drops to zero, current increases tremendously, which can be identified in the monitor. More over sparks will produce in those regions. PRESSURE TESTING: In pressure testing the water is filled inside the insulator with high pressure. And test is carried out. Weather insulator can with stand the pressure. DIMENSION TESTING: In dimension testing, the quality department will inspect the dimension of the insulator with the customers requirement diagrams. Visual inspection is carried out with some measuring devices. CANTILEVER TESTING: In cantilever testing, one end of the insulator is fixed and in transverse direction force is applied to the other end to check the bending moment of the insulator. BEAM TESTING: In beam testing, the epoxy jointed insulator is fixed at two ends and load is given at the joined region to inspects weather the joint can withstand the load or not.

ASSEMBLY
After the inspection, accepted good quality insulators are come to assembly section. In assembly section the insulator grip attaching end and the flange internal regions are painted with bituminous paint, it helps to have grip between the clay portion and the flange hardware. Two types of flanges are there galvanized flanges and anodized flanges. After the bituminous paint is applied it should be dry for 24 hours. In assembly section 3 machines are there for assembling. Two types of cement are used to join the hardware and clay insulator. Namely, Dallcrate SVN

Dall crate needs to dry for 4 hours after its applied SVN needs 45 minutes to dry. Dall crate is local Indian made cement. SVN is imported cement. For applying the cement Adapter plates are used at both ends of the clay regions. It is removed after the cement gets dried. Cement needs water to strengthen its bond, so curing region is there. They pour water in the cemented region continuously at regular intervals. For SVN cement it takes 24 hours for curing, while Dall crate takes 3 days for curing. PACKING In packing session, the insulator is packed with plastic cover and placed in a wooden box. Then it is carried to the customer through the respective transport. QUALITY The quality system, certified for compliance to ISO 9001 (achieved in 1991) is used as the primary tier of product and process control. This is supplemented by comprehensive usage of other techniques including SQC, SPC, PDCA and Continuous Improvement projects in all areas of operations.

HR-Human Resource HR human resource department is responsible man power in the industries. They have the right to appoint or dismiss the employer.
HR CHAT WORK MEN CHART

DGM
2 years

Trainees ( 3500 INR ) Probation ( 3900 INR ) Confirmation ( 5500 INR )

Manager
6 Months

Deputy Manager 3- Executives

ENGINEERING EXECUTIVES CHART STAFF CHART

1 Year

Training ( 9500 INR )

1 Year

Training ( 6020 INR )

Probation
6 months 6 months

Probation

Confirmation

Confirmation

FINANCE In finance department, the expensive spent by a person for the sake of companys purpose can be refunded by present envoys with the respective form. Two types of forms are there namely, Reimbursement form Allowance form

REIMBURSEMENT FORM: This form is to submit with envoys to the finance department in sake for refund of money spent by a person for companys purpose. ALLOWANCE FORM: It is to get funds from the company to do something for the companys sake. After the act they should submit the envoys to the finance department. PURCHASE In order of needed some parts to purchase for companys purpose. Indent form should be filled with Bill of materials. For example: In assembly department, need to purchase flanges means. Quantity, product code etc... All should be filled and Bill of materials should be enclosed with Indent form. STORES Storing is the main purpose of stores. Also they inspect the incoming material through the following stages. Receipt Inspection Storage Issuing

In reception stage, security will check the package is belongs to W.S industries are not. Then it is transfer to stores. There they will inspect the bill of material only. Then it will be tagged with yellow card. It means its under inspection. Then those who order to purchase will be called off to check the quality and other required parameters. If the product is ok, green tag will be tagged and it is stored in the stores. If it is not satisfied it will be red tagged and return back to the suppliers. While needed we fill the BOM form and get the required materials from the stores. Three more types of forms are there namely, ID form Returnable gate pass Non-returnable gate pass

ID FORM: If the department takes extra amount of products, then they can return the extra products which are idle to the stores by ID form. RETURNABLE GATE PASS: If any break down happens, the machine to be serviced. For that it needs a returnable gate pass. It contains address and date of return and other details of the service station. NON-RETURNABLE GATE PASS: If anything goes out of the company which may not return further, it needs a non-returnable gate pass. For example: Any machines is needed for the Chennai plant means, they takes from Vizag plant. On those conditions they may not return it. For those conditions Nonreturnable gate pass is used. MECHANICAL & ELECTRICAL Mechanical department controls the maintenance of the plant. From gear box to CNC machines all the mechanical components are maintained and serviced by this mechanical department. Electrical department, electrical line is about 33 KVA, it is step down to 440 Volts. Most of the machines using 3 phase connections. Shuttle Kilin is supported with UPS back up. Two

diesel generators are used for back up power supply. Electrical components and machines are maintained and serviced by electrical departments. UTILITY & SAFETY In utility section air compressor, regulators and filters are maintained. Depends on the need of the region the necessary devices and components are used. Fire line Red color Water line green color Air line - Blue color Diesel line Brown color LPG line Yellow Color

In case of safety, helmet, shoes, gloves, nose mask. Eye glasses are commonly suggested. Depends on the region of working atmosphere the precaution and the safety equipments varies.