Detailed Project Report on porcelain pin insulators (11kv & 33kv)

PORCELAIN PIN INSULATORS (11KV & 33KV) 

[CODE NO.4256] 

Electrical Insulator is used in electrical system to prevent unwanted flow of current to the earth from its supporting points. The insulator plays a vital role in electrical system. Electrical Insulator is a very high resistive path through which practically no current can flow.  In transmission and distribution system, the overhead conductors are generally supported by supporting towers or poles. The towers and poles both are properly grounded. So there must be insulator between tower or pole body and current carrying conductors to prevent the flow of current from conductor to earth through the grounded supporting towers or poles.

The main cause of failure of overhead line insulator, is flash over, occurs in between line and earth during abnormal over voltage in the system. During this flash over, the huge heat produced by arcing, causes puncher in insulator body. Viewing this phenomenon the materials used for electrical insulator has to possess some specific properties. The materials generally used for insulating purpose is called insulating material. For successful utilization, this material should have some specific properties as listed below:

• It must be mechanically strong enough to carry tension and weight of conductors. 

• It must have very high dielectric strength to withstand the voltage stresses in High Voltage system.

• It must possess high Insulation Resistance to prevent leakage current to the earth.

• There physical as well as electrical properties must be less affected by changing temperature

Porcelain in most commonly used material for overhead insulator in present days. The porcelain is aluminum silicate. The aluminum silicate is mixed with plastic kaolin, feldspar and quartz to obtain final hard and glazed porcelain insulator material. The surface of the insulator should be glazed enough so that water should not be traced on it. Porcelain also should be free from porosity since porosity is the main cause of deterioration of its dielectric property. It must also be free from any impurity and air bubble inside the material which may affect the insulator properties.

The combination of porcelain and other minerals allows electricity to pass without reacting with nearby electrical conductors. Since porcelain does not conduct electricity, especially when combined with other non-conductive materials, it makes the ideal material for insulators. Porcelain insulators typically contain large concentrations of some other mineral like alumina or clay. The combination of porcelain and other minerals allows electricity to pass without reacting with nearby electrical conductors. This not only ensures greater safety, but enables the electricity to pass without losing any of its charge. Since porcelain does not conduct electricity, especially when combined with other non-conductive materials, it makes the ideal material for insulators.

An insulator used to insulate a wire, such as a pin on a utility pole from a physical reinforcement is known as a Porcelain pin insulator. The pin insulator is used in power delivery for voltage up to 33kV. It is positioned on the cross arm of the supporting tower. The pin insulator has grooves at the top to keep the conductor. The conductor is connected to the insulator by the angled binding wire of the same material as the conductor on the top groove on the straight-line positions and side groove. A lead thimble is cemented into the insulator body to receive the pin.

Depending on the application voltage, the pin insulator may be one part, two parts, or three parts. As the voltage is higher, the thicker the insulator requires to have enough insulation.

Pin insulator comprises two main components: porcelain and galvanized bolt-in steel. The bolt is joined by cementing at the foundation. The insulator against bolts may be secured by several techniques.

Porcelain insulators provide years of reliable and consistent performance in the most rugged environments. Porcelain insulators are the most widely applied insulator in electrical transmission & distribution systems. From salty seaside substations to highly corrosive petrochemical facilities along the equator, porcelain insulators enable continued operation at the designed voltages.

The global Pin Porcelain Insulators market was valued at USD million in 2020 and it is expected to reach USD million by the end of 2027, growing at a CAGR of % during 2021-2027.

It is intended to prepare a Feasibility Report to install a Porcelain Insulators (11KV and 33KV) production facility with an installed capacity of 600000 Pieces / Year as a Green Field Project.

COST ESTIMATION

Plant Capacity                                      2000 Pieces/Day

Land & Building (8490 sq.mt.)  Rs. 4.07 Cr

Plant & Machinery                              Rs. 11.93 Cr

Working Capital for 3 Months    Rs. 4.35 Cr

Total Capital Investment                  Rs. 21.33 Cr

Rate of Return                                    72%

Break Even Point                               39%

• • INTRODUCTION
• 
  
• • USES/APPLICATIONS/ADVANTAGES
• 
  
• • DIFFERENCES BETWEEN PORCELAIN PIN INSULATOR AND POST 
• 
  
•         INSULATOR
• 
  
• • TYPICAL SPECIFICATIONS OF PORCELAIN PIN INSULATORS
• 
  
• • TESTING/APPLICABLE CODE & STANDARD
• 
  
• • MARKET OVERVIEW
• 
  
• • RAW MATERIALS
• 
  
• • DESIGNING CONSIDERATION OF ELECTRICAL INSULATOR
• 
  
• • PROCESS STEPS/PROCESS FLOW SCHEMATIC
• 
  
• • BROAD EQUIPMENT DETAILS
• 
  
• • PRODUCTION LINE – RAW MATERIAL SOURCE/EQUIPMENT 
• 
  
• • APPLICATION
• 
  
• • UTILITY REQUIREMENT (ESTIMATED) - MONTH
• 
  
• • PLANT & MACHINERY SUPPLIER/TURNKEY CONSULTANTS
• 
  
• • WASTE GENERATION & MANAGEMENT/GREEN BELT
• 
  
• • HEALTH SAFETY AND ENVIRONMENT
• 
  
• • ANTICIPATED ENVIRONMENTAL IMPACTS
• 
  
• • MITIGATION MEASURES (PROPOSED)
• 
  
• • HEALTH SAFETY & ENVIRONMENT
• 
  
• • SAFETY & OCCUPATIONAL MEASURE
• 
  
• • PROPOSED IMPLEMENTATION SCHEDULE
• 
  
• • PROJECT FINANCIALS
• 
  
• • CORRESPONDENCES (WITH CLIENT)

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)