ELECTRICAL WIRE & CABLE
[CODE NO.4054]
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.
TYPES OF ELECTRICAL WIRES
There are two main types of wires: solid or stranded.
A solid wire is a single conductor that is either bare or insulated by a protective colored sheath. It offers low resistance and is perfect for use in higher frequencies. When inside a covering there are many thin strands of wires twisted together, it is called a stranded wire. Stranded wires are used where flexibility is important because which the wire can be used for a longer period. This type of wire have larger cross-sectional area than solid wires for the same current carrying capacity. Stranding is process of twisting together of small wires to form a single larger conductor. Used to provide flexibility, ease of handling and vibration resistance.
Copper Wire
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
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
ELECTRICAL CABLE
A cable is defined as the set of conductors, insulators, sheaths and armor protection or shielding, specifically built to carry the current both for energy transportation and for signal transmission.
PVC COPPER CABLE
PVC insulated cables & wires are the ultimate medium for the distribution of electricity. The PVC cables are used for the power distribution in all types of electric wiring, control cables, telephone cables and signaling in Railways. The PVC cable has mostly replaced VIR and CTS cable in domestic as well as industrial wiring due to its long life, moisture resistance, etc
The individual insulated conductors are covered with PVC coatings providing additional electrical and mechanical protection. The cables are suitable for use in sub-station, distribution systems, industrial installation, house wiring and street lighting, etc.
House wire is the simplest of cables and most basic in its construction, manufacture and use. It consists of only two components, viz. conductor (mostly copper) and insulation (mostly PVC) involving three operations – wire drawing, stranding, bunching and extrusion. Before the advent and subsequent extensive use of vinyl compound as insulating materials, vulcanized rubber was most commonly used insulating material for domestic wire as it was for other types of cables. It served the industry and the users very well for several decades until replaced by PVC (Poly Vinyl Chloride).
Property
1. The long-term permissible operation temperature of the conductor shall not be higher than 70℃.
2. Conductor maximum short circuit ((less than 5 second) temperature shall not be higher than 160℃.
3. The cable is not limited by drop in level when being laid, and the environment temperature shall not be lower than 0℃.
4. Perfect chemical stability, resistant against acids, alkalis, grease and organic solvents, and flame retardance.
5. Light weight, perfect bending properties, installed and maintained easily and conveniently.
Application
With the characteristics of stable capability, advanced technology, broad material resources, low price, good flexible and easy to lay and maintain, the PVC Insulated and Sheathed Power Cable are suitable to be laid for distribution line with A.C.50HZ and rated voltage up to 1kV.
COST ESTIMATION
Plant Capacity 20 MT/Day
Land & Building (4000 sq.mt.) Rs. 4.49 Cr
Plant & Machinery Rs. 92 Lac
Working Capital for 2 Months Rs. 49.03 Cr
Total Capital Investment Rs. 54.61 Cr
Rate of Return 35%
Break Even Point 32%
- INTRODUCTION
- TYPES OF ELECTRICAL WIRES
- THERE ARE TWO MAIN TYPES OF WIRES: SOLID OR STRANDED.
- COPPER WIRE
- PROPERTIES
- PROPERTIES OF COPPER WIRE:
- ELECTRICAL CABLE
- PVC COPPER CABLE
- PROPERTY
- APPLICATION
- ADVANTAGES
- ADVANTAGES OF PVC CABLES
- SOME OF THE MAJOR ADVANTAGES OF PVC CABLES
- CONSTRUCTION
- CONDUCTOR
- 1. SOLID/STRANDED
- A. SOLID
- B. STRANDING
- 2. CIRCULAR/ SHAPED
- A. CIRCULAR
- B. SHAPED
- INSULATION
- THE FOLLOWING COLOUR CODE IS USED FOR IDENTIFICATION:
- LAYING UP
- INNERSHEATH
- A. EXTRUDED INNERSHEATH
- B. TAPPED INNERSHEATH
- ARMOURING
- OUTERSHEATH
- USES AND APPLICATION
- B.I.S. SPECIFICATION
- PROCESS FLOW CHART
- MANUFACTURING PROCESS
- (1) DRAWING
- (2) ANNEALING
- (3) STRANDING
- (4) INSULATION
- (5) QUALITY CONTROL
- CABLES ARE MANUFACTURED AND UNDERGO THE FOLLOWING TESTS:
- (A) TYPE TEST
- 1. THE FOLLOWING TESTS ARE TYPE TEST OF ELECTRICAL POWER CABLE.
- PHYSICAL TESTS FOR INSULATION AND SHEATH
- (B) ACCEPTANCE TEST:
- (C) ROUTINE TEST:
- CONDUCTOR RESISTANCE TEST OF ELECTRICAL POWER CABLES
- TEST FOR THICKNESS OF INSULATION OF POWER CABLE
- APPARATUS REQUIRED TESTING FOR THICKNESS OF INSULATION OF POWER CABLE
- PROCEDURE FOR TESTING OF THICKNESS OF INSULATION OF POWER CABLE
- ANNEALING TEST FOR WIRES AND CONDUCTORS
- PROCESS OF ANNEALING TEST FOR WIRES AND CONDUCTORS
- TENSILE TEST OF CONDUCTORS
- APPARATUS REQUIRED FOR TENSILE TEST:
- METHOD OF TENSILE TEST OF CONDUCTORS
- PROCEDURE
- PERSULPHATE TEST OF CONDUCTOR
- WHY COPPER WIRES ARE TINNED?
- METHODS
- METHOD A:
- METHOD B:
- TEST SPECIMEN FOR TINNING TEST (FOR METHOD B)
- WRAPPING TEST FOR CONDUCTORS
- (6) COILING AND PACKING
- MARKET POSITION
- MARKET OVERVIEW
- EXHIBIT 1: CONSUMER ELECTRICALS SECTOR VALUATION SNAPSHOT
- EXHIBIT 2: CABLES AND WIRES INDUSTRY REGISTERED 23% CAGR IN VOLUME TERMS LED BY STRONG DEMAND FROM POWER DISTRIBUTION
- EXHIBIT 3: C&W MARKET IN REVENUE TERMS IS EXPECTED TO
- DOUBLE OVER FY18-23E
- EXHIBIT 4: CABLES AND WIRES DEMAND DRIVERS
- EXHIBIT 5: COMPANIES (HAVELLS & FINOLEX) WITH HIGHER SHARE OF HOUSING WIRES HAVE REGISTERED STRONG MARGINS EXPANSION
- EXHIBIT 6: DISTRIBUTION CHANNEL
- EXHIBIT 7: MOST OF THE ELECTRICAL PLAYERS HAVE DIVERSIFIED OVER THE LAST FIVE YEARS
- EXHIBIT 8: DEMAND FOR COPPER IS QUITE HIGHER IN EV
- EXHIBIT 9: NITIAYOG EV PLAN 2030
- EXHIBIT 10: EV INFRASTRUCTURE DEMAND FORECAST
- EXHIBIT 11: TRANSMISSION PROGRESS AS ON FEB’19
- EXHIBIT 12: FEEDER SEGREGATION PROGRESSING STEADILY
- EXHIBIT 13: METRO CONSTRUCTION SENDS ARE EXPECTED TO ~DOUBLE OVER THE NEXT FIVE YEARS
- EXHIBIT 14: RAILWAY ELECTRIFICATION WORK SANCTIONED
- EXHIBIT 15: INFRASTRUCTURE SPEND GROWTH TO REMAIN HIGH
- EXHIBIT 16: URBAN POPULATION AS A % OF TOTAL POPULATION
- EXHIBIT 17: HOUSE SANCTIONED UNDER PMAY (URBAN)
- EXHIBIT 18: HOUSE SANCTIONED UNDER PMAY (GRAHMIN)
- EXHIBIT 19: SHARE OF HOUSEHOLDS OF TOTAL POWER CONSUMPTION
- IS EXPECTED TO INCREASE OVER THE NEXT 5 YEARS
- EXHIBIT 20: SHARE OF ORGANIZED PLAYERS WILL IMPROVE TO 74%
- BY FY23E
- PLANT LAYOUT
- PRINCIPLES OF PLANT LAYOUT
- MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE
- SERVICE ARE:
- PLANT LOCATION FACTORS
- PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
6. TRANSPORTATION:
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TOTAL LOAD:
8. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
SUPPLIERS OF PVC COPPER WIRE
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF COOPER WIRE ROD
SUPPLIERS OF PVC COMPOUND CABLE GRADE
SUPPLIERS OF PACKAGING MATERIALS
SUPPLIERS OF PLANT AND EQUIPMENTS
SUPPLIERS OF WIRE DRAWING MACHINE
SUPPLIERS OF PVC EXTRUSION PLANT
SUPPLIERS OF ANNEALING FURNACE
SUPPLIERS OF WIRE STRANDING MACHINE
SUPPLIERS OF WIRE STRANDING MACHINE
SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
SUPPLIERS OF EOT CRANES
SUPPLIERS OF DG SETS
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF ETP PLANTS
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF WEIGHING MACHINE (PLATFORM TYPE)
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
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)
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