Mohityadavreport
Mohityadavreport
Mohityadavreport
Company's authorized capital stands at Rs 40.0 lakhs and has 100.0% paid-up capital which is
Rs 40.0 lakhs.
Syska Miterr Private Limited is majorly in Business Services business and currently, company
operations are active.
Company is registered in Chandigarh (Punjab) Registrar Office. Syska Miterr Private Limited
registered address is H NO. 9 CANTONMENTTHE MALL AMRITSAR Amritsar Punjab-143001.
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COPPER WIRE MANUFACTURING PLANT OVERVIEW
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3 STEP MANUFACTURING PROCESS
In the first phase of the manufacturing process, copper wire is drawn to the proper size in a two-step
drawing process, and then it is annealed and coated with polyethylene insulation. It is tested before
passing on to the next manufacturing phase
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In the second manufacturing phase, insulated copper wire is first twisted into wire pairs, and then the
twisted wire pairs are combined by a strander.
Step-3
Jacketing the cable
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FLOW GRAPH FOR MANUFACTURING OF COPPER WIRE
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DIFFERENT TYPE OF WIRE MANUFACTURING
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DESCRIPTION OF THE WORK
The electrical current in a conductor causes a voltage drop and power losses. The
temperature rise in the cable caused by the losses must be kept within certain limits in order
not to shorten the service life of the cable. The temperature limit varies with the type of
cable, or more precisely the type of insulation. The best way to keep the temperature within
limits specified for the type of cable, is to choose the conductor cross-section so that the
cable and its surroundings with the actual continuous load, achieve thermal balance at a
temperature below or equal to the temperature limit recommended. Cable type and size
should be selected keeping in view the following: -
(1) Application.
(2) Working voltage; earthed or unearthed neutral system.
(3) Load current, load factor, starting duty and frequency.
(4) Installation method.
(5) The environment in which the cable has to operate.
(6) Short circuit current and system protection.
(7) Acceptable voltage drops
(8) Economies.
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How the above factors influence on the choice of cable?
1. Application: The application of the cable determines the basic factors for the choice of
cable type and the rules according to which it must be manufactured. Following are the
2. Conductor materials
No doubt copper is better conductor material owing to its high electrical conductivity and
other electrical/mechanical properties but due to its high cost and scarcity, researches are
being carried out to find other cheaper and abundant metals which may be a close substitute
to copper in electrical application. Aluminum conductors are being used in place of copper
conductors for the past many years and have proved to be quite satisfactory. The lower
conductivity of an Aluminum (61 % of the annealed copper) results in increased dimensions
of the cable and ultimately of conduits and fittings for the same current carrying capacity as
that of a copper conductor cable. Aluminum conductor cables although bigger and
somewhat stiffer when lower number of wires is used for the conductor than the equivalent
copper conductor cables, are still flexible enough to be installed where a copper conductor
cable was formerly used. The advantages of the lighter weight offset the disadvantages of
larger sizes for a given capacity. The use of Aluminum conductor cables should be preferred
as far as possible. The use of flexible copper conductor is recommended where very high
degree of flexibility is required as in the case of mines etc.
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3.Insulating materials:
The right type of insulation material for a particular use depends upon the voltage grade,
4. Metallic Sheathing:
Either pure lead or different lead alloys are used for Sheathing of PILC cables and each has
its own advantages. The most common and popular alloy is lead Alloy 'E'.
5.Bedding and Serving materials: In case of PVC cables the normal bedding and serving
materials are PVC compound. The normal bedding and serving in case of PILC cables
consist of a combination of an impregnated paper, cotton and Hessian tapes and bituminous
compound. These materials provide protection against corrosion of armor and lead and are
suitable in great majority of installations. However, in special cases where severe chemical
corrosion is to be encountered, the use of PVC bedding and PVC serving is recommended.
6.Armoring:
The purpose of armor is to provide mechanical protection to the cable and to facilitate
earthling for safety requirements. This also carries phase to ground fault currents of the
system safely. Double steel tape provides good mechanical protection but when in addition
longitudinal stresses are encountered during the installation or in service, steel wire/strip
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armoring is recommended for vertical armoring should be preferred. Double wire runs, river
crossing, cables laid on bridges and mine shafts etc. where longitudinal stresses are
expected.
3. The current rating is, in general, the decisive factors for fixing conductor cross-section.
But in certain applications where intermittent load is required, it is more relevant to use the
4. The power cables must be capable of carrying, the required normal full load current
continuously under the site conditions throughout the year. Therefore, the current ratings
depending upon -
5. (A) Chemical substances in the environment might cause special stringent requirements
(B) If it is necessary to reduce the propagation of fire along cable route combined with
low corrosivity, toxicity and smoke generation characteristics for cables, "FRLS' cables
(Flame Retardant low Smoke) with thermoplastic or thermosetting material or fire survival
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cables with elastomeric material should be used. These types of cables are designed with
special composition of protective sheath materials, and by using beat barrier tapes etc. for
(C) Short circuit current together with duration of short circuit determines the short
circuit energy the cable insulation has to with stand thermally certain cases a larger size of
cable then the cable required for normal full load current may be needed to match system
short circuit current levels. Voltage drop is also a major factor in deciding the conductor
size of the cable. The cross section of the cable should be chosen such that voltage drop of
the cable for the given route length does not exceed the statutory requirement.
(D) Naturally, the most economical construction and the size of the cable consistent with
required current carrying capacity and laying condition must be selected. Thus, the
selection of particular type of cable i.e. PVC, XLPE, PILC or rubber and the particular
material for screening, sheathing, bedding, armoring or serving etc. out of many choices
available depends upon the usages, laying and climatic conditions. The design of the cable
for a application must be optimized taking into account all the above-mentioned factors. In
case expert guidance in this respect is desired, please contact UCI Technical Service
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Manufacturing Process
The overall stages of manufacturing consist of the following different types of processes.
2) Insulation -Paper/PVC/Rubber/XLPE/Fluoroplastic/Polyethylene
3) Laying
4) Impregnation
5) Lead Sheathing
8) Sheathing
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The details of above manufacturing processes are as given here under: -
Wire Drawing:
Wires of different sizes are drawn from Aluminum/Copper rods on wire-drawing machines.
The size(diameter) of wire depends upon the over-all cross-sectional area of the ultimate
cable under manufacture as well as the flexibility requirement. Annealed copper Wires for
flexible rubber cables are then tinned before they are released for next process. The tinning
is done by passing the cleaned cu. wires seated with the flux through molten tin both. The
excess of tin adhering to wire surface is wiped out by means of wipers Stranding - The Al or
Cu. wires or tinned copper wires as the case may be are bunched/stranded together. The
direction of stranding of alternate layers is always kept in opposite direction in order to have
tight and balanced configuration of wires. The standard Conductor may be compact circular
INSULATION
(1) PVC - Different type of PVC compounds are used for required Physical & electrical
properties and continuous operating temperature of cables. PVC compound extruded over
conductor by extrusion process on different sizes of extruders as per the size of conductor.
In line to extrusion process H.V. testing (Spark testing) is being done to check the quality of
extruded core.
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2. Rubber - Natural or synthetic rubber-based compounds are prepared to meet the
physical & Elec. properties and continues operating temp. of cable. Various types of rubber
compounds are then extruded over the conductor as per the requirement of the customer.
3. Paper insulation - In this case insulated paper tapes are lapped on conductor. The
grade of cables. The top layer of paper tapes is suitably numbered for core identification.
XLPE – Pep cables have become very much popular now a day. These cables are
replacing paper-insulated cables right from low voltage grade to extra high voltage grade. In
these cables two types of constructions are used ie screened and unscreened. 11 KV and
above grade cables are all screened. Conductor screen, insulation and insulation screen
are generally applied in one operation called dual-tandem process. M/s Universal Cables
Ltd is one of the pioneer cable manufacturers of XLPE cable up to 132 KV grade cables in
INDIA.
Vulcanization/Cross-linking: Rubber and XLPE cables are vulcanized after extrusion. This
process is done just after extrusion on CV/CCV/PLCV lines. This process is done to
compounds. In some cases, batch vulcanization is carried out for rubber cables and low
Laying up of cables.
The insulated cores are laid up along with filling material and twisted to get approximate
circular Cable. A binding tape is also provided to hold the fillers and maintain the circularity
of laid up cables. In case of paper-insulated cables if the cables are belted type, belt
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insulation is done along with laying up process by providing required no. of paper tapes and
in screened type cables copper woven fabric tape is provided over laid up cores.
Impregnation process:
Paper insulated cables need a special process known as impregnation. The function of this
process is to extract moisture out of paper insulation and impregnate the insulation with
moisture resistant insulating compound. Heating the Cable under vacuum for some period
and then filling the insulating compound over cable within the impregnating vessel do this
process. The cycle of drying flooding and cooling etc. depends on size and voltage grade of
Procedure adopted for drying and impregnation of paper-insulated cables comprises the
following stages.
required period
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The compound used for impregnation is a petroleum product and has excellent electrical
Lead sheathing
After impregnation, lead sheath is applied over the paper-insulated cables. This process is
done by sleeve extrusion (pipe extrusion). The object of Lead sheathing is to prevent the
entry of moisture in the impregnated cable while maintaining the flexibility of cable.
Inner Sheathing/Bedding
PVC and Rubber insulated cables are provided with inner sheathing over laid up cores as
bedding for armoring. In case on PVC cables inner sheathing may be done by lapping
PVC/PE tapes or by PVC extrusion but in case of rubber insulated cables rubber extrusion
Armoring
installation. HI is done by providing galv. round steel wires or galvanized steel strips or
double steel tapes over the bedded cables. Though the main function of armoring is to
protect the cable from outside mechanical damages to the cable, but it also serves the
purpose of carrying the short circuit current produced during system failure or any type of
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Sheathing/Serving: -
After armoring or in case of un-armored cables, the laid and bedded cables are provided
with a protective sheathing of extruded PVC or PE sheath. Paper insulated cables are
generally provided with a fibrous lapped serving but PVC or any other type of extruded
Telecommunication Cables: Apart from power and control cables, telephone cables are
also manufactured. These cables are generally called PIJF cables meaning Polyethylene
Insulated Jelly Filled cables. In these cables copper wire of suitable size is insulated with
Polyethylene. Two insulated wires are twisted together to form a pair. Required numbers of
such pairs are grouped together and filled with special moisture resistant jelly. The filled
cable is than screened with polythene laminated aluminum foil and sheathed with LDPE
compound. The cable is finally armored with galvanized double steel tapes and jacketed
Final testing: -
All cables are rewound in proper size wooden/steel reels and sent to testing section where
all the cables are subjected to rigorous electrical and physical tests. Both the ends of cables
after testing are sealed and given a unique identification number. These are then handed
Quality control
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In syska cables quality is maintained by following a in built quality system which is based on
A property organized system of control of quality of product and process is followed for the
efficient production of product acceptable in all respects to the customer. Products are
tested and processes are controlled at all stages of manufactures from raw material to the
finished stage. In addition, certain standards procedures are adopted in order to ensure that
Electrical and mechanical departments are responsible for the periodic maintenance of all
breakdowns and thereby loss of machine and men hours. Both these departments are also
looking after breaking down maintenance and installation &commissioning of new machines
and instruments. These departments also carry out calibration of various electrical and
mechanical instruments.
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IMAGES OF REAL TIME MACHINE USED FOR MANUFACTURING
1.RBD MACHINE(Rod Breakdown machine)
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Functional view of RBD
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2.MWD(Multi Wire Drawing)
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BUNCHER (Wire bunching machine)
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ELECTRICAL WIRE PVC INSULATION PRODUCTION MACHINE
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COILER(For coiling the final insulated copper wire)
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SPARK TESTER
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COILING AND PACKGING SECTION
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FINAL PRODUCT READY FOR DISPATCH
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CONCLUSION
Hence in the last I can say that taking training in such an organization proved to be very
beneficial for me. I learnt quite a lot about processes of cable making, selecting of cable
material, and how different processes like bedding, armoring, serving are done. In short i got
The first phase of training has proved to be quite fruitful. It provides an opportunity to
The architecture of company has various units. They are linked and working of whole plant
is controlled make the student realized that engineering is not just learning the structure
description and working of various machines. But the greater part is planning proper and
management.
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REFERENCES
2.Internet
3.www.reelex.com
4.www.researchgate.com
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