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Introduction
BHEL is the largest engineering and manufacturing enterprise in India in the energy related/ infrastructure sector, today. BHEL was established more than 50 years ago, ushering in the indigenous Heavy Electrical Equipment in India a dream that has been more than realized with a well recognized track record of performance. The company has been earning profits continuously since 1971-72 and paying dividends since 1976-77. BHEL manufactures over 180 products under 30 major product groups and caters to core sector of the Indian economy viz., Power Generation and transmission, Industry, Transportation, Telecommunication, Renewable Energy etc. The wide network of BHELs 14 manufacturing divisions, 4 power sector regional centers, over 100 project sites, 8 service centers and 18 regional offices, enables the company to promptly serve its customers and provide them with suitable products, system and services- efficiently and at competitive prices. The high level of quality and reliability of its products is due to the emphasis on design, engineering and manufacturing to international standards by acquiring and adapting some of the best technologies from leading companies in the word, together with technologies developed in its own R&D centers. Strategic plan 2012 for ensuring a sustainable profitable growth for the company has been drawn up to enable the companys turnover to grow from US $ 4 billion to 10 billion by 2011-12. The plan focuses on the capacity and capability enhancement that will leverage the companys effort in its core area of power, supported by industry, transportation, transmission, exports and spares and services businesses.

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A world- class Engineering Enterprise Committed to Enhancing Stakeholder value.

The company is striving to give shape to its aspirations and fulfill the expectations of the country to become a global player. The greatest strength of BHEL is its highly skilled and committed 44,500 employees. Every employee is given an equal opportunity to develop himself and grow in his career. Continuous training and retraining, career planning, a positive work culture and participate style of management all these have engendered development of a committed and motivated workforce setting new benchmarks in terms of productivity, quality and responsiveness. BHEL has acquired certifications to Quality Management Systems (ISO 9001), Environmental Management Systems (ISO 14001) and Occupational Health & Safety Management Systems (OHSAS 18001) and is also well on its journey towards Total Quality.

BHEL has Installed equipment for over 90,000 MW of power generation -- for Utilities, Captive and Industrial users. Supplied over 2,25,000 MVA transformer capacity and other equipment operating in Transmission & Distribution network up to 400 kV (AC & DC). Supplied over 25,000 Motors with Drive Control System to Power projects, Petrochemicals, Refineries, Steel, Aluminum, Fertilizer, Cement plants etc. Supplied Traction electric and AC/DC locos to power over 12,000 kms Railway network. Supplied over one million Valves to Power Plants and other Industries. The mission of our BHEL is: To be an Indian Multinational Engineering Enterprise providing Total Business Solution through Quality products, System and Services in the fields of Energy, Industry, Transportation, Infrastructure and other potential areas. .

BHEL INSULATOR PLANT, JAGDISHPUR

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A UNIT OF BHEL

Insulator Plant, Jagdishpur was inaugurated on 3rd March,1984 by then Prime Minister of India Late Smt. Indira Gandhi , as 11th manufacturing unit of BHEL in Sultanpur District, 78 Kms. Away from Lucknow on Lucknow-Sultanpur high-way. BHELs glorious experience in the Ceramic field with technical collaboration with M/s. NGK, Japan, the world leader in insulator technology, set the pace for the commissioning of this plant. This unit has been provided with the most modern and sophisticated facilities. With a view to ensure financial viability of Insulator Plant, Jagdishpur, the Unit of BHEL planned to diversified to the production of Industrial Ceramics namely Ceralin in the year 1989-90. The Ceralin production for commercial use was started in 1993-94. The ceralin was the product being manufactured in BHELs Electroporcelain Division, Bangalore and Insulator Plant Jagdishpur got a technologically established and commercialised product . For increasing the production of ceralin BHEL Insulator Plant installed a modern Car Bell type High Temperature Kiln in the March 2009. This HTK has firing capacity of 4 to 5 ton of products. BHEL Insulator Plant, Jagdishpur is the leading manufacturer of High Tension Porcelain Insulators and Distribution insulators like Bobbin/Shackle, Guy/Stay/Strain, Pin, Cap & Pin type Post Insulators in the country. They are equipped with highly sophisticated plant and machinery. This division also offers Wear Resistant High Alumina Ceramic Lining material for Power, Steel, Cement and Mining Industries as well as a wide range of Industrial Ceramics. BHEL Insulator Plant, Jagdishpur has attained ISO 9001 certification in 1994, ISO 14001 and OHSAS 18001 certifications in 2002 for its well established systematic production systems, standards, environmental management and safety management. In addition of these BHEL IP has got certification of merit in RKBNQA in the year 2008-09. This shows the dedication of each individuals of unit for the quality of works and products.

OBJECTIVES AND GOALS OF INSULATOR PLANT 1. 2. Appropriately Integrate Manufacturing with Technology development and further technology development with marketing. Thrust on Export Marketing.
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3. 4. 5.

To maximize the Business in Ceramics Area by Business Development , Engineering and Technology Management (Technology acquisition/Technology development/ Job to job tie up etc.). To ensure earning on capital employed through efficient and effective use of resources and enhance stake-holders interests. To produce quality products in the field of Ceramics and attain & sustain a good market share in Ceramic Industry of India.

PRODUCT RANGE:Products:

. DISC INSULATORS:

Porcelain Insulators for 300 KN, HVAC, 160 KN HVDC, Post and Pin, Fog and Anti Fog varieties for transmission lines. Insulators for 33 KV & 11 KV. 420 KN disc insulators has been developed and will be the product of next year. Hollow bushings are the main new product of Insulator plant.

Customers:

PGCIL, NTPC, NHPC, State Electricity Boards, Power Line Construction Contractors & Export Customers.

CERALIN BENDS Cerelin Bends of different specifications as required by the customers. Customers: NTPC Limited and Other Power Generation companies.

2. Production:
Production department has following sections: (a) Slip House: In slip - house the raw material are loaded per composition into "ball-mills". In ball -mills 'river -pebble' are put as grinding -media. When ball -mill is operated the grinding media and raw material produced the file paste called 'slip'. This slip is the input for the 'filter- presses to produce the 'cake'. This cake is output of slip -house and serves as input for manufacturing /Jiggering.

(b) Jiggering (Manufacturing): - The input for Jiggering station is cake produced by slip -house. The cake are fed into 'pug-mill', which under vacuum homogenous Cake in cylindrical form, which is cut automatically in required length (as per product), called pugs. These pugs are fed into Jiggering machines, which at first go impart initial shape of insulator shells. The secondary or final die gives the final shape

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shell. These green stage shells are dried in CD (chain-dryer). After drying these shells are taken out of modes and send for finishing. (c) Finishing &TD: - The unfinished shells are finished on MCBL (Multi Purpose Vertical Lathe Machine). These finished articles are loaded onto racks fed into "Tunnel -Dryer" or MDC. The output of the dryer is totally dried insulator or shell.

(d) Glazing: - The dried insulator shells are finished for minute tracks serration the accepted articles are glazed on glazing machines with required thickness of glaze.

(e) Kiln: - It works on oxidation - reduction process. The glazed articles are loaded into refractory wagons and put into firing. Through OTK (oil tunnel kiln). The gap between the loadings of two wagons is 50 to 60 minutes depending upon the product composition. The fired and loaded shell are inspected for the defects and on the basis of their merit accepted /rejected.

(f) Assembly & Testing: - The accepted fired shells .are tested for their mechanical strength for loading hydraulically .The hydraulic accepted shells are tested for thermal shock endurance .The O.K. shells are spread with 'Bituminous Paint' on the head and the recess portion accommodate MCI (malleable cast iron) cap/pin. The painted shells are assembled and cured insulators are put under routine mechanical and electrical testing. A sample of insulator is tested and put under destructive test .The tested accepted insulator are packed and stored on specified vans.

(g) E&D (Engg. and Development): - This department provides the required technical input /damages to a planning and procurement department. This also works hands with commercial for tendering.

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(h) Ceralin: - Ceralin stands for ceramic lining. The metallic bends, pipes, orifices and other equipment of power plant are subjected to heavy temperature and erosion due to abrasive materiel .To avoid this untimely failure of the component lining of abrasive resistance materiel like high Alumina ceramic product is done. At IP, Jagdishpur, components are lined with the ceramic product to avoid the erosion.

Production Flow Chart for Ceralin:

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B Finished Product Scra Material P a llAssembly / RawMill Spray Drier Weighment & Metallic Casings pLoading / Slip House O Loading In Firing Lining Dispatch Tile Pressings W (Ceralin) HTK D E R

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Main functions of the WEX department:

1. Break Down Maintenance: A state of M/C or equipment when it cannot perform its desired function. Breakdown Maintenance procedure:

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The intimation of breakdown of the equipment is given by the user department in BREAKDOWN MAINTENANCE REQUISITION slip.The requisition indicates the shop / section, description / name of the m/c or equipment, nature of trouble, date and time of reporting the breakdown. The intimation is also received by telephone and verbal communication and followed up with the written requisition as above. The intimation of breakdown is further entered in the log book SHOP BREAKDOWN LOG BOOK. The section-in-charge / section supervisor deputes the artisans to attend the breakdown. On diagnosing the fault and analyzing the reason the artisan attends to the breakdown by repairing or rectifying the equipment. Spares / consumables as and when required are also replaced / replenished. The technical / managerial support from supervisor and or executive-in-charge as and when required for diagnosis / analysis of the fault is also rendered. After repairs by the authorized person the user department and intimation of handing over, the user / production department representative checks the equipment & takes over the equipment by confirming its restoration, date and time.

The entries in the SHOP BREAKDOWN LOG BOOK is updated with details of person attending the breakdown, nature of trouble, spares consumed if any, handing over time etc.

- Daily break down report is fed in wex server (Break down 08-09) and is analyzed. List of equipment under breakdown or preventive maintenance inclusive of carried over is prepared daily in MAINTENANCE STATUS REPORT on computer by Area-in-charge. This status is communicated by company wide e-mail to the concerned for monitoring on day to day basis. A copy of the format for MAINTENANCE STATUS REPORT is placed at Annexure-3 of this document. 2. Preventive Maintenance In the plant there are many critical machines. To upkeep these machineries maintenance department does Preventive Maintenance. The frequency of Preventive Maintenance activities is fixed by Maintenance department and scheduling of maintenance is done in co-operation with user departments, so that failures / breakdowns can be minimized.

Preventive Maintenance procedure:

1.

A List of critical equipments identified for carrying out scheduled preventive maintenance. An annual programme for the preventive maintenance is drawn at the beginning of the financial year.

2. The preventive maintenance schedule for these identified critical equipments is drawn out. 3. The schedule of preventive maintenance is given to user department. Further the user department is informed of the equipment due for preventive maintenance one week in advance through an
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INTIMATION FOR PREVENTIVE MAINTENANCE. This intimation is not sent for the equipment under the control and operated by WEX. 4. The preventive maintenance is carried out as per the pre-defined check sheets. The check sheet is broadly classified under MECHANICAL and ELECTRICAL. The machine is run on no load / load as the case may be after carrying out the preventive maintenance. The equipment is then handed over to user department with due verification / confirmation.
5.

In the event of user department not able to spare the machine for preventive maintenance or WEX is unable to carry out the preventive maintenance as per schedule, the reasons for delay and re-scheduling of the preventive maintenance is recorded in the annual preventive maintenance programme. By mutual consultation the user and WEX decide upon the re-scheduled preventive maintenance program and is carried out accordingly.

3. Calibration: The calibration of instruments, gauges, measuring equipment etc., used in the manufacturing process of Insulators & Ceralin and other allied activities like inspection, testing and maintenance are calibrated in the in-house facility. The activity of Calibration is detailed under Procedure for Calibration.

4. Analysis of repeated Breakdowns: The repeated breakdowns observed are analyzed, investigated and the results of investigation are recorded. These identified corrective actions are then implemented in the respective areas & monitored to ensure its effectiveness through the Breakdown Analysis.

5. Condition Monitoring: In plant, the condition of the machineries is regularly monitored and recorded by Maintenance Department along with user departments. If any abnormality is seen in any machines / parts, then required maintenance is carried out by Maintenance Department. This type of maintenance is called as condition monitoring. Example of condition monitoring: {Condition Monitoring of Roto pump}
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Maintenance person record the noise level of bearing of roto pump Abnormal noise recorded Intimation was given to the production to release the roto pump After releasing, whole pump is dismantled and conditioned / bearing changed. The roto pump was again assembled Trial run was taken.

1. Retrofitting: Implementing new technology in old machinery is called as retrofitting. If the performance of any machine is not satisfactory, then maintenance department study the machine and identify the parts due to which, performance is decreased. Then replacement of those parts with improved technology parts is done by Maintenance Department itself or by sub-contracting. Example of retrofitting: {Introduction of Planetary Gear Box in Ball Mill} Existing open geared ball mill was studied The retrofitting job, to be done, is designed (Vendor Catalogue was referred) Specification of the planetary drive was prepared (Vendor Catalogue was referred) Budgetary offers were taken from vendors Approval was taken of the budgetary offer & project was sanctioned Indent was prepared After procurement, installation of the planetary gear was done. Trial Run was taken. Improvements were observed and recorded.

7.Purchase Indenting: For maintenance of machineries WEX Department needs spares/components/ parts/machineries. For purchasing these items purchase indent is prepared by maintenance department and send it to the MM department for procurement of material. This is the responsibility of WEX planning to make available all material at right time and right quality and quantity. Inventory management of WEX department is taken care by WEX planning. 8. Subcontracting of Works: There are two types of sub-contracting
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Type I Subcontracting of material-Components offload to manufacturer or party.

Type II Subcontracting of Job-Labours contract (For welding/fabrication etc.)Consumables for this type of works are supplied by BHEL.

9. Installation (Project Works) The Works Engineering & Services department carries out the activity of indenting, evaluation of offers, assisting in procurement, inspection / testing and co-coordinating the installation activity of the new equipment / plant. The installation of the equipment including erection & commissioning of the equipment / plant may be carried out by the supplier of equipment as a part of the purchase contract or through sub-vendors / sub-contractors. On successful completion of the installation activity the COMMISSIONING REPORT for the equipment is issued.

Global Services-Engineering & Commercial Global services engineering as well as commercial inclusive of services after sale are accorded the utmost importance in BHEL. BHEL has a service network with regional headquarters in the four regions of the country. They are backed by core Power Sector Technical Services and Field engineering Group. Services are provided in the following significant areas: Residual Life assessment (RLA) Due to aging, material grade of sets degrade as a function of time dependent material damage mechanisms such as creep, fatigue, corrosion, erosion, wear, embrittlement etc. The residual life of components is evaluated through sophisticated NDT stress analysis & metallurgical techniques. It fare warns the impending failure and helps in reducing costly plant breakdowns by recommending replacement of defective components, retrofits etc.

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Renovation & Modernisation(R&M) As a step towards continuous effort for updating the existing designs BHEL, Haridwar offers a number of renovation and retrofit modules. Some of these are:

Rewinding of old turbo generators having bituminous stator winding of 50-235MW range, with class F insulation system. Rewinding of old turbo generators rotors with latest Class F insulation system. Stator water polishing unit.(Retrofit) Control and Instrumentation for auxiliary systems for 200/210/235MW turbo generator sets. Moisture measuring equipment.(Retrofit) Refrigeration type gas drier.(Retrofit) Provision of auxiliary bearing in 210MW THW type generators.(Retrofit) Provision of top ripple springs in stator slots of THW type turbo generators.(Retrofit) Grounding brush monitoring.(Retrofit)

Major Overhaul BHEL undertakes periodic annual maintenance of turbo generators and also on specific customer requirement. Spare supply BHEL has a system of advanced planning for spares by which it is in a position to offer spares in time. Web Based User Friendly Catalogued spares management system is available for easy ordering by customers. Troubleshooting Prompt door step service is provided to the customer for any problem faced in power sector viz. Turbo generator damages, malfunctioning of equipments etc. On-line condition monitoring for condition based maintenance of turbo generators continuous on line monitoring and diagnosis is provided.

INTRODUCTION NETWORK:-

TO

B.H.E.L.

COMMUNICATIONS

In past few years the field of communication has been developing with no leaps or bounds. It has become a necessity of each human being to be connected with each other. Telephone is rapidly becoming a tool to quench this thirst. In Automatic Telephony, operators are not required to establish connections manually between the different calling and the called subscribers as are required in
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the case of manual telephone systems. In these system subscribers those selves establish required connections by operating the different switches placed at the central place known as the EXCHANGE from their telephones at remote place from it. The automatic telephone systems are rapidly replacing manual ones due to their outstanding merits over the latter types, some of which are enumerated below:

In Automatic Telephony higher level of secrecy is maintained due to absence of Operators who can overhear the conversation if they like in the manual telephone Systems. The working of an Automatic Telephone system does not depend for its efficiency on the personal efficiencies of the operators. There is no possibility of the calls being missed or wrong metering being done due to faults of operators or due to phonetic errors between the subscribers and the operators.

As no operator is required, the running cost of the exchange is reduced.

Fig.3 - Telephonic System

TELECOMMUNICATION
BHEL manufactures EPABX and MAX systems based on C-Dot technology and has plans to make other ranges of telecommunication equipment also. These are basically used for connecting links between various modules like peripherals, exchange and its equipments. It is necessary to run a number of internal cables of suitable conductors between the following stages and frames:1. Handset to exchange's cable chamber 2. Cable chamber to M.D.F.
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3. M.D.F. to I.D.F. 4. I.D.F. to Number Block 5. Number Block to Exchange Equipment 6. Between two exchanges 7. Between two cities 8. Between two countries Prior to advent of Electronic Exchanges interconnection of various circuits are made by mechanical contacts that are operated by mechanical movements produced by the attraction of an iron armature of an electromagnet or by the operation of an electric motor. There are some disadvantages of such systems for using mechanical contacts, due to following reasons: Contacts are subjected to wear and tear. Require adjustments time to time. Maintenance is highly precise. Prone to corrosion. etc.

But now-a-days Electronic Exchanges are used. In Electronic exchange electronic devices effect the inter-connection between different transmission circuits and Electro-mechanical relays and switches are dispensed with. Such electronic devices remove difficulties associated with mechanical contacts. The greatest advantage of using electronic devices in place of electromechanical devices is that no time is loosed in making a connection and a very high speed of operation is possible.

Fig.4 Telephone Network, BHEL

ELECTRONIC EXCHANGES
Electronic Exchanges are of two types:
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1. Tone type 2. Pulse type

1. Tone type:

In this type of exchange sine waves are used. Their speed of dialing for a given number is more than that of Pulse type. In this type of exchange square wave is used due to which the dialing speed is lesser. The telephone apparatus used for both types are different in construction. But now days both types of apparatus are integrated in a single machine in which switch-over can be made via a selector switch.

2. Pulse type:

TONES USED IN MODERN TELEPHONY Dial Tone: When handset is picked up from the cradle, then Dial tone is heard if a free line is available. This means that the instrument is ready to send the signals to the exchange. When the subscriber takes up the receiver then signals are sent M.D.F. then to I.D.F., line Number block and to Peripherals where in various line-cards are mounted in a shelf. When corresponding number on the line-card is free then the Ringer section of that Peripheral generates a signal called tone. This tone is a continuous burble sound of 400 Hz modulated by 25Hz and is sent to the calling subscriber as soon as his line seizes the free line. The subscriber must not dial before receiving this tone; otherwise he is liable to get wrong connection. If he does not get this tone, he should try after some time.

Busy Tone: When the called subscriber is engaged with other call, this tone is heard. It consists of a sound of 400 Hz which is regularly interrupted at equal intervals. It is generally on for 0.75 sec and off for also 0.75 sec Ringing Tone: When a number is dialed then telephone of the called subscriber starts ringing. Calling subscriber should get this information and this is indicated by sending ringing tone of interrupted 400 Hz supplies modulated by 25 Hz and its durations are generally equal to the duration of ringing current, which rings the bell. It may be 0.4 sec on, 0.2 sec off or it may be 0.75 sec on and 0.75 sec off and so on. When this ringing tone is received, the calling subscriber knows that the connection is completed and that the bell of the called subscriber is ringing. Number Unobtainable Tone: This tone is sent when the number dialed cannot be obtained. If any subscriber dials which is not actually connected to the exchange, this indication is send. This is also a tone of 400 Hz with interruption of 200 ms at every 3 sec. Now-a-days push button type telephone apparatus are used. This apparatus can be exploded into following sections: 1. Ringer section
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2. Speech section (Transmitter and Receiver section) 3. Voltage limiter section

From telephone exchange two wires or connectors run for each number, in which one is neutral and the other is main or positive. For the telephone circuit to work the necessary supply is provided by the exchange. Like other circuits telephone also operates when a circuit is established between calling and called subscriber. When one dials a number then the corresponding relays at the exchange established a circuit automatically. The telephone exchange supplies 40-60 volt DC and 110/20 Hz to operate this circuit. This is required because of voltage drop that may creep in long transmission wires. As soon as the handset is picked-up this 48-volt DC supply is available at voltage limiter section, dialing pulse generator and speech section. In telephone dialing two types of frequencies are used which are: High band tone (1216 Hz. to 1645 Hz.) Low band tone (701 Hz. to 936 Hz.)

Frequencies used in Telephony The numbers from 1 to 5 falls in low band and 6 to 9, 0 falls in high band. Till the handset is on-hook, the ringing section of the apparatus is on through telephone line but on lifting the handset the ringing section becomes off, also the dialing and speech section becomes ready. On lifting the handset first the dial tone is received which is amplified by the amplifier of speech section. When a number is pressed on the keyboard, the dialing pulses are made on and off according to the number dialed. For example if 5 is pressed then dialing pulses are made on and off 5 times. This process can be heard on the receiver. There is a gap of 1 sec. between consecutively pressed numbers.

How the telephone call is made: Telephone call is characterized into two sections: 1. Outgoing calls: Generally a voltage of 48V-60V DC always remains on the telephone line but as the handset is picked-up the voltage limiter drops this voltage to 9-12V on hearing the dial tone it is confirmed that the apparatus is ready to work and after dialing the number a ringing pulse is send to the called party. When the calling party picks-up the handset the billing meter of the exchange becomes activated. There is a counter in the exchange, which counts the pulse and converts them into calls. 2. Incoming calls: These are just opposite of outgoing calls. In the incoming calls the telephone detects the ringing signal from the exchange and provides the ring. At the instance of ringing signal, there remains a voltage of 75-110V/20 Hz on the telephone. A high voltage (AC) is sent from the ringer section of the exchange to start the ringer circuit of the telephone. When the ringing signal is received it should be properly isolated as it may give a shock. This ringing circuit is on until the handset is not picked-up at the called party. The duration of this tone, if unattended, is 1
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minute after which an engage tone is heard. After lifting the handset a circuit is established and a call is made. There are various powers providing circuits available in the exchange to run the circuitry. These are broadly categorized in two categories: Outside the exchange Inside the exchange Outside the Exchange: Since the voltage supplied in Indian Subcontinent is 220-volts/50 Hz AC but for the normal working of the exchange 48(46-53) volts of DC is required. Hence a Rectifier circuit, backed with battery array for power-failures, is used. This rectifier block not only rectifies the input supply but also works as a battery charger. It is known as Float rectifier cum charger. Battery backup is utilized for smooth operation of the exchange during power failures. For battery back-up lead acid battery array is used in parallel to the supply from the rectifier block, so that during power failures the exchange supplies are not terminated. Inside the Exchange: Inside the telephone exchange various types of power supplies are used for powering various modules (for example: - Line-cards, Ringer). Some of them are: -5 V 12 A +5 V 12 A +12 V 6A.

From M.D.F. a number of cables, based upon the requirement of a place, are connected to cabinets. On the cabinets these cables are divided into cables of 20 pairs. Now every 20 pair cable goes to the distribution box (D.B.). At the D.B. this 20 pair cable is further divided into two parts of 10 pairs each. These pairs are then connected to the subscriber ports via jumpers. The line from these ports then goes to the subscribers through single pair cables which are usually of P.V.C. type. These wires are connected to the instrument via Rosette-Box.

M.D.F
This frame serves the following purposes: BHEL, Jagdishpur

Fig.6 Inside Exchange

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It is place where both external and internal cables are terminated. The external individuals cable carry conductors from subscribers who are necessarily from the same locality and as such their numbers cannot be in numerical order. On the other hand, the internal cable conductors come from apparatus side in numerical order. This cross-section between the two cables is done on the M.D.F through jumper wires. It carries all the protectors used in the exchange. The different protectors that are used are (a) Fuses, (b) Heat coils, and (c) lightning protectors. This M.D.F is an ideal place for testing purpose. Both the internal and the external cables are available at this frame and, therefore, both external and internal wiring and lines can be tested for this purpose.

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Fig.8 New IDF

I.D.F
These frames like M.D.F. consists of a large number of verticals with horizontal crossarms fitted with tag blocks at both the ends. The cable from M.D.F. is terminated on the multiple sides from where connections are extended to metering and from the exchange side cables are run to the respected line-cards. The two tag blocks are joined by means of jumper wires as in the M.D.F., so that any subscriber can be given connection to any uniselector on the line-card. The subscriber and, therefore, their uniselector are divided into different groups and it is necessary for these groups to originate more or less the same amount of traffic for smooth distribution among different trunks.

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TELEPHONE LINES
In BHEL three types of telephone lines are used. They are: MAX Lines EPABX Lines C-DOT Lines

MAX Lines: Before MAX Ex. Lines are used only Internal Exchange. But New (CORAL) MAX lines are used for both internal (Intercom) and external communication links BHEL. EPABX Lines: EPABX lines are used for both internal and external communication links in BHEL. If the user wants to dial outside the periphery of BHEL, he can use these lines. There are about 500 lines available here. These lines are distributed in 17 line-cards with 24 line numbers in each. Its I.D.F. section has 40 tag blocks. 96 numbers available here are connected via digital lines in which a host of facilities are provided that can be accessed using code 69. C-DOT Lines: These the lines are direct

telephone lines from C-DOT The facility they provide is called DID (Direct Inward Dialing). It has 24 lines and any BHEL number starting with digit 5 can be accessed using code 48.

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CONNECTION TYPES
Types of Connections: 1. With wires i.e. Cables 2. Wireless Microwave Links through Satellite Cables: Two types of Cables are used. They are: 1. Underground cables: These types of cables run under the earth and are basically used to connect the exchange to the subscriber's Distribution Box (D.B.). They are further of two types based upon their construction and the insulating material used. a. Paper core A.T.C. (Armored Tin Cable) b. Jelly filled A.T.C. (Armored Tin Cable) 2. Overhead cables: These types of cables are used to connect the equipments inside the exchange and to connect the peripheral devices to the subscriber's Distribution Box (DB) They are generally of P.V.C. type. In an exchange, based upon the number of conductor pairs, following types of cables are used: Single Pair cable 2 Pairs cable 5 Pairs cable 10 Pairs cable 20 Pairs cable 50 Pairs cable 100 Pairs cable Color-coding: TYPE Single pair 2 Pair cable 5 Pair cable COLOR OF WIRES Blue-White Blue-White/Orange-White Blue-White/Orange-White/Green-White/Brown-White/Grey-White

10 Pair cable Blue-White/Orange-White/Green-White/Brown-White/GreyWhite/Blue-Red/Orange-Red/Green-Red/Brown-Red/Grey-Red 20 Pair cable Blue-White/Orange-White/Green-White/Brown-White/GrayWhite/Blue-White-blue/Orange-White-Blue/Green-White-Blue/BrownWhite-Blue/Gray-White-Blue/Blue-White-Orange/Orange-WhiteOrange/Green-White-Orange/Brown-White-Orange/Gray-WhiteOrange/Blue-White-Green/Orange-White-Green/Green-WhiteGreen/Brown-White-Green/Gray-White-Green.

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For 100 pairs cable the color-coding is same as that of the above 20 pairs cable except that the mate color is changed after each bunch of 20 pairs.

PAIRMATE COLOR 1st 20 pairs White2nd 20 pairsYellow3rd 20 pairsBlack4th 20 pairsViolet5th 20 pairs Red

General faults occurring in an Exchange

There are mainly two types of faults that often occur in the Exchange. These are basically 1. Faults that occur from Line 2. Faults that occur due to Instrument 1. Faults that occur from Line Due to line three types of faults may occur. They are categorized as under: 1. Break fault: They are also called as Disconnection faults. They can occur in the connectors at home, in line or in exchange. In common they are broadly called as "Telephone is dead". 2. Loop fault: They are also called as Line-Shorting faults. In this fault connectors are shorted prior the instrument forming a local loop. If unattended for a long time they may cause severe damage to the Exchange. 3. Earth fault: This fault may occur due to: wetting of connectors Water in Rosette-Box Weak insulation or Oxidation of copper wire Connectors can either touch from earth, with other connector or with any conductor (such as metallic table, frame etc.)
Problems that can occur due to line faults: Fig.9 Automatic Line Tester

1. 2. 3. 4. 5.

Subscriber cannot dial a number. Ring Trip i.e. connection from the exchange breaks after one ring. False Ring Low speech One sided speech

Faults that occur due to instrument:

These may be: The number is not being dialed One way speech Receiver coil is faulty

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1. Faults that occur due to instrument

Plunger or Push switch faulty. Dial tone breaks after two or three rings. From

second subscriber bell is heard to be going but at first subscriber only dial tone is heard. Instrument circuitry faulty. When loop or earth fault is received than exchange can be affected so it is wedged as soon as possible because if not wedge for longer it can damage linecard too. To sense these faults first line-side is checked and then exchange side is checked at exchange. If however exchange side is correct then line faults after detection are handed over to the concerned lineman for further checking.

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LIST OF SPECIAL EXCHANGES

1.

USER

FEATURES

ON

VARIOUS

MAX (Coral India Pvt. LTD, NOIDA)

Manufacturer: Jeumont Schinedier, France Capacity: 2700 lines 89-xxxx to pick up a call ringing at another location 2 Parties conversing, any party can dial 3rd party, then Conversation among them Hang-up. The party on line now talks to 3rd party. While speaking with a party: (From Pulse Instrument: -- If CALLER requires dialing 3rd party during conversation and maintaining talks, then dial 4.) (From Tone Instrument: -- If CALLER requires dialing 3rd party during conversation and maintaining talks, then flash, and dial 4.)

Call Pick Up: xxxx. Call Transfer:

Party Conference:

Malicious Call Trace: Dial 29 during conversation, to trace a malicious call From a MAX Extension. Then enquire from 4999 or 4424. Appointment Reminder: Dial 80-xx-yy {xx=hrs, yy=min}. To Cancel: Dial 27.

1. EPABX = ALCATEL 4400

Manufacturer: ALCATEL, FRANCE Capacity: 500 lines (96 DIGITAL, 404 ANALOG) Technology used: PCM - TDM Dial # before no. {If instrument is not tone enabled) Hook FLASH: Do Hook Flash On hearing prompt "Please dial." Dial the no., wait for party to respond, and then disconnect. FLASH (from Tone mode instrument.) or 2 (from Pulse During converse put the 1st party on HOLD. Then, dial a 3rd party and speak.

Tone Mode Dial: Call Transfer:

Enquiry Call: mode)

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Broker Call:

(After ENQUIRY CALL): Dial 1 To go BACK & FORTH, between two parties (one party in conversation & other On HOLD) While talking to 1st party, first make ENQUIRY CALL (Put on hold){FLASH from Tone; or 2 from Pulse}. Dial 5 to book auto-callback when a busy PABX hangs up. (To cancel auto-callback request: Dial 67 or/and 848)

Conference-3 Party: Auto Callback:

Password Modification: 847-0000-xxxx (0000=old password; xxxx = new Password). This facility is available on STD enabled extensions only. Last caller callback: 851 {to ring the last unattended PABX Caller}

Appointment Reminder: 852 then dial the time as {xx (hr) xx (min)} To cancel: 853 Last no. Redial: Redial Button. Call Pickup: extension. Call-Park / Retrieve: from a different set. 854 User can use this if instrument doesnt have a 72 - XXXX to pick up a call ringing at another It is used during an incoming or outgoing call, to speak

(To park from own (speaking) set: FLASH-855- dial own extension number. Then Hang-up". The call is now parked, and the other party is kept on hold. (To pick up from a different set: 855- dial own extension number) (To pick up from own set (later, if not taken elsewhere) 855)

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OPTICAL FIBER SYSTEM

Fiber optical transmission medium is fast emerging as an alternative and strong competitor to coaxial cables in telecommunication networks. Long distance data transmission in electrical cables suffers from ground loop problems. The merits of the optical fiber stem from the fact that the basic material used in their construction is nonmetallic and electrically nonconductive.

Fig.10 Broadband Optical Fiber System

In contrast, the nonmetallic and totally dielectric fiber optical cable are immune to radio frequency another electromagnetic interferences. Ground loop and common mode voltage problem do not exist and data can be transmitted between points of vastly different potential. In optical cables the information is transmitted by packets of photons which have no charge. There is no possibility of sparks or short circuit when a fiber is cut. The bandwidth high compared to that of the electrical cables. The standard RG-58 coaxial cable has bandwidth distance product of a typical optical fiber is about 100 MHz-Km. Fiber cables are about the thickness of a human hair any dirt obstructing the optical port causes poor transmission. The thin dimension results in a low weight for given length when compared to electrical cables. However, being thin and somewhat brittle in nature, fiber tend to break easily if bent beyond a certain limit a direct viewing into the optical point can be harmful to the eyes.

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MAINTENANCE
The subject of maintenance of Automatic Telephone Exchange can be broadly divided under two categories: 1. Prevention of Service Failures. 2. Location of Faults and their removal. Prevention of Service Failures can be done in following ways: 1. Suitable design and adoption of suitable adjustment standards of the equipment parts of the exchange can minimize failures in service. 2. Some preventive measures may also reduce service failures viz. keeping the rooms dust free, maintaining temperature and humidity under tolerable limits using air-conditioners. 3. Routine inspection, routine tests and routine adjustments also help in preventing service failures. When faults occur in some parts of the exchange, they should be detected and removed as quickly as possible. Various tools are also used to check the faults in the telephone lines and for checking fault inside the exchange.

BHEL, Jagdishpur

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