FLEXIBLE PVC WIRE AND CABLES
(HOUSING WIRING MANUFACTURING)
[CODE NO.3756]
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.
COST ESTIMATION
Plant Capacity 2 Ton/Day
Land & Building (1500 sq.mt.) Rs. 2.14 Cr
Plant & Machinery Rs. 1.46 Cr
Working Capital for 1 Month Rs. 1.96 Cr
Total Capital Investment Rs. 5.80 Cr
Rate of Return 51%
Break Even Point 43%
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
APPLICATIONS
B.I.S. SPECIFICATION
OVERVIEW OF PVC WIRE AND CABLE
INDIAN WIRE AND CABLE MARKET
CAPEX IN KEY SEGMENTS FY15-19 - TOTAL = RS. 8,56,020 CRORES
PRIORITIZATION OF RAILWAY LINES
METRO RAIL GROWTH
METRO PROJECTS PIPELINE - ORDERING EXPECTED OVER FY17-19
GENERAL METRO RAIL CAPEX BREAKDOWN
GROWTH IN TRANSMISSION SECTOR
GROSS BLOCK (FIXED ASSETS) OF MAJOR TELECOM SERVICE PROVIDERS
IMMENSE GROWTH IN RENEWABLES CAPACITY LED BY SOLAR
GROWING MIX OF RENEWABLES IN GENERATION AHEAD
INVESTMENT REQUIRED TO ACHIEVE 175GW RENEWABLE ENERGY
TARGET BY FY2022
KEY SECTORS FOR INVESTMENT UNDER SMART CITIES MISSION
PRODUCT PROFILE
GOVERNMENT REGULATIONS
GOVERNMENT INITIATIVES
DEMAND-SUPPLY DYNAMICS
DEMAND GROWTH
DEMAND DRIVERS
IMPORT EXPORT TREND
IMPORT EXPORT TREND
CAPACITY ADDITION
PRICE TREND
COMPETITIVE SCENARIO
RESOURCE RISK
FINANCIAL RISK
EXPORT DATA OF PVC COPPER FLEXIBLE
IMPORT DATA OF INSULATED COPPER CABLE
IMPORT DATA OF PVC COPPER WIRE
GLOBAL MARKET POSITION WIRE & CABLES
WIRE & CABLE DEMAND
EUROPEAN TRENDS FOR WIRE & CABLE DEMAND, 2010-2016
KEY TRENDS IN END USE MARKETS – CONSTRUCTION
ANNUAL GROWTH OF PRODUCTION IN CONSTRUCTION, 2010-2016
(% YEAR-ON-YEAR CHANGE)
KEY TRENDS IN END USE MARKETS – TELECOMMUNICATIONS
KEY TRENDS IN END USE MARKETS - POWER INFRASTRUCTURE
EU-28 WIRE & CABLE APPARENT CONSUMPTION, 2010 – 2016
(‘000 TONNES)
EU-28 WIRE & CABLE APPARENT CONSUMPTION, 2010 – 2016 (€ MILLION)
WIRE & CABLE SUPPLY
EUROPEAN TRENDS FOR WIRE & CABLE SUPPLY, 2010-2016
ITALY AND GERMANY HAVE THE HIGHEST NUMBER OF CABLE PLANTS,
EACH WITH MORE THAN 100 OPERATIONAL SITES
GERMANY IS THE LARGEST PRODUCER, REPRESENTING 17%
OF TOTAL EU-28 PRODUCTION
TOP WIRE & CABLE PRODUCERS IN THE REGION
TOP WIRE & CABLE COMPANIES, 2015
EU-28 WIRE & CABLE PRODUCTION, 2010 – 2016 (‘000 TONNES)
EU-28 WIRE & CABLE PRODUCTION, 2010 – 2016 (€ MILLION)
WIRE & CABLE TRADE
EU-28 WIRE & CABLE TRADE, 2010 – 2016 (€ MILLION)
EU-28 WIRE & CABLE TRADE, 2010 – 2016 (€ MILLION)
EU-28 TRADE HAS RETURNED TO OVERALL NET IMPORT, AFTER
BECOMING A NET EXPORTER BETWEEN 2010 AND 2014
MANUFACTURERS/SUPPLIERS OF PVC COPPER WIRE
OUTLINE OF MANUFACTURING PROCESS
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 TO TEST 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
SEQUENCES IN WIRE & CABLE MANUFACTURING
WIRE DRAW IS FIRST STEP
TWISTING AND STRANDING
CABLING AND JACKETING
CABLES TESTED BEFORE SHIPPING
CABLING INSTALLATION & MAINTENANCE
SUPPLIERS OF RAW MATERIALS
COPPER WIRE ROD
PVC COMPOUND CABLE GRADE
PACKING MATERIALS
SUPPLIERS OF PLANT AND EQUIPMENTS
WIRE DRAWING MACHINE
PVC EXTRUSION PLANT
ANNEALING FURNACE
WIRE STRANDING MACHINE
WIRE STRATNING MACHINE
ELECTRICAL MEASURING INSTRUMENTS
EOT CRANES
DG SETS
POWER TRANSFORMERS
COOLING TOWER
ETP PLANTS
AIR POLLUTION CONTROL EQUIPMENTS
AIR CONDITIONING EQUIPMENTS
AIR COMPRESSORS
AIR COMPRESSORS
WEIGHING MACHINE (PLATFORM TYPE)
MATERIAL HANDLING EQUIPMENTS
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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