Detailed Project Report (DPR) on submersible copper winding wire

SUBMERSIBLE COPPER WINDING WIRE

[CODE NO.4368]  

Wire is used to carry the current from one place to another A wire is a single conductor (material most commonly being copper or aluminium) while cable is two or more insulated wires wrapped in one jacket. Multiple conductors that have no insulation around would be classified as a single conductor.

Copper Wire is a single electrical conductor manufactured out of Copper Ore. This widely used conductor can either be insulated or uninsulated. Having a moderate conductivity, it’s used to transfer electricity with low voltage. Electrical wiring in buildings is the largest market for the copper industry worldwide. As per estimation, around half of the copper mines is consumed in manufacturing electrical wire and cable conductors

Properties of Copper Wire

• Tensile Strength

• Electrical Conductivity

• Strength and Ductility combination

• Creep resistance (it doesn’t change much due to heat)

• Corrosion resistance

• Co-efficient of thermal expansion

• Ease of installation

• Thermal conductivity

• Ability to be soldered

Copper wire is an essential material for motor and transformer winding. Copper wire is available in different gauges (32 gauge to 18 gauge). The gauge of the copper wire depends upon the winding required for the specific motor or transformer. The wire having conductor diameter from 0.500 to 4.000mm, is suitable for submersible motor winding. There is a heavy market for copper wire/enameled copper wire in motor and transformer manufacturers and this wire is also used in rewinding of motors and transformers. Reasons for its wide use is that the copper has resistance to atmospheric corrosion because of the form ation of uniform layer of oxide on the surface of metal.

Benefits of Using Copper Wire

Copper wire is the most preferred wire today for umpteen critical industries, like electronics, telecommunications, construction, marine, and soforth. These great features of Copper wire have made it an obvious choice for these industries.

Flexibility: Flexible in nature, Copper wire can be Moulded, cut and blend to suit the needs. Such need is widely required in industries such as marine and construction.

Conductivity: Copper is the second highest conductivity element, with silver being the most. Because of the extremely high electrical and thermal conductivity features of Copper wire and less expensive than silver, make Copper wire the most sought after wire for industries

Melting Point: Since Copper displays absolutely high melting point, it suits to the needs of industries like electrical and construction.

Strength: Copper wire is very strong as it is made out of high tensile Copper Ore. In industries like telecommunication where wire is used for signal transmission across long distance, wire of similar strength is required.

Compatible: Copper wires such as bare copper wire and tinsel copper wire are highly compatible with one another, and they can form brisk mixture should there be need.

One of the primary factors that marked the evolution of the human beings is the advent of technology. What started as the invention of wheel has got us to ace age of technology and innovations. The use of technology can be experienced everywhere near us. However, the basic factor that drives most of the technical machines is electric current. In order to transfer the charges bearing the current, the use of conducting wires is extremely important. The current conducting wires should have the required features as per the needs that would make them a proper candidate. One such wire is the submersible winding wire.

Basic Features of the submersible winding wire:

The submersible winding wires are also known by the name of poly winding wires. There are many types of machinery where mechanical abrasion and corrosion is very common. Along with that, some industrial machines are also exposed to high temperature. In addition, there are various kinds of machinery, which are required to carry out their functions underwater. In such conditions, one should not call for the regular wires because such extremities can cause the wires to break down thus inviting un-called for hazards. It is for such situations where the submersible winding wires comes to rescue so that the regular operations performed by the machines can be carried on smoothly and safely.

Specification of Copper Submersible Motor Winding Wire

COST ESTIMATION

Plant Capacity                                    1.2 MT/Day

Land & Building (4000 sq.mt.)  Rs. 10.64 Cr

Plant & Machinery                              Rs. 91 Lac

Working Capital for 2 Months    Rs. 4.97  Cr

Total Capital Investment                   Rs. 16.71 Cr

Rate of Return                                     47%

Break Even Point                                32%

• INTRODUCTION
• PROPERTIES OF COPPER WIRE
• BENEFITS OF USING COPPER WIRE
• BASIC FEATURES OF THE SUBMERSIBLE WINDING WIRE:
• PRODUCT DETAILS:
• SPECIFICATION:
• USES AND APPLICATION
• USES OF SUBMERSIBLE WINDING WIRE:
• B.I.S. SPECIFICATION
• PROCESS FLOW CHART
• MANUFACTURING PROCESS
• 1. WIRE DRAWING
• 2. ANNEALING
• 3. ENAMELLING
• 4. QUALITY CONTROL AND STANDARDS:
• A. DIMENSION TEST:
• C. ELECTRICAL RESISTANCE TEST:
• C. ELONGATION TEST:
• D. SPRINGINESS TEST:
• E. FLEXIBILITY & ADHERENCE TEST:
• F. HEAT SHOCK TEST:
• G. CUT THROUGH TEST:
• H. SOLVENT TEST:
• I. BREAKDOWN VOLTAGE:
• J. CONTINUITY OF INSULATION:
• K. TEMPERATURE INDEX:
• M. ABRASION RESISTANCE (UNIDIRECTIONAL):
• N. TAN DELTA BENDING POINT:
• O. SHRINKAGE TEST:
• P. HIGH VOLTAGE TEST:
• R. INSULATION RESISTANCE TEST:
• 5. COILING AND PACKING
• POLLUTION CONTROL:
• ENERGY CONSERVATION:
• MARKET POSITION
• COPPER WIRE DRAWING AND ENAMELLING
• TYPE OF ENAMELED COPPER WIRES
• BENEFITS OF USING COPPER WIRE
• Ø  FLEXIBILITY:
• Ø  CONDUCTIVITY:
• Ø  MELTING POINT:
• Ø  STRENGTH:
• Ø  COMPATIBLE:
• APPLICATIONS:-
• PROPERTIES OF COPPER WIRE
• THE WIRE DRAWING PROCESS
• KEY PLAYERS:-
• TOP 10 WINDING WIRE MANUFACTURERS
• 1. AKSHAY INSULATED CONDUCTORS
• 2. ALLIED WIRE INDUSTRY
• 3. APPLE INSULATED WIRES
• 4. ESKAY WIRES MANUFACTURING
• 5. GANPATI ENGINEERING INDUSTRIES
• 6. KHAITAN WINDING WIRE
• 7. RR SHRAMIK
• 8. STERLING ENAMELLED WIRES
• 9. VEER INDUSTRIES
• 10. VIDYA WIRES
• MARKET GROWTH
• PLANT LAYOUT
• SUPPLIERS OF SUBMERSIBLE COPPER WINDING WIRE
• SUPPLIERS OF RAW MATERIALS
• SUPPLIERS OF COPPER WIRE ROD
• SUPPLIERS OF POLYETYLENE COMPOUND CABLE GRADE
• SUPPLIERS OF PACKING MATERIALS
• SUPPLIERS OF PLANT AND MACHINERY
• SUPPLIERS OF WIRE DRAWING MACHINE
• SUPPLIERS OF POLYETHYLENE EXTRUSION PLANT
• SUPPLIERS OF ANNEALING FURNACE
• SUPPLIERS OF WIRE STRANDING MACHINE
• SUPPLIERS OF WIRE STRATNING MACHINE
• SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
• SUPPLIERS OF DG SETS
• SUPPLIERS OF EOT CRANES
• SUPPLIERS OF POWER TRANSFORMERS
• SUPPLIERS OF ELECTRICAL PANEL
• SUPPLIERS OF ELECTRIC MOTOR
• SUPPLIERS OF COOLING TOWER
• SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
• SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
• SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
• SUPPLIERS OF AIR COMPRESSORS
• SUPPLIERS OF PLATFORM WEIGHING MACHINE
• SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
• SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
• SUPPLIERS OF SHOT BLASTING MACHINE
• SUPPLIERS OF JIGS AND FIXTURE
• SUPPLIERS OF SUBMERSIBLE WATER PUMP

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)