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G(SILVASSA)
POWER CABLES(1-4CORES ,10-
1000MM2)
• ARMOURED/UN ARMOURED
• SCREENED(H.T) /UNSCREENED(L.T)
CABLE CROSS-SECTION
CUSTOMER ORDER : P 2020187
P 2 0 2 0187
CODE DESCRIPTION:
A2XFY(T)
A-ALUMINIUM CONDUCTOR
2X –XLPE INSULATION
F-FLAT STRIP ARMOURING
Y-PVC OUTER SHEATH
(T)- TAPPED INNER SHEATH
(P)- EXTRUDED INNERSHEATH
CABLE CONSTRUCTION :
COPPER -------
ALUMINIUM A
XLPE 2X
PVC INSULATION Y
AL ROUND ARMOUR Wa
AL FLAT ARMOUR Fa
D1 3
D2 0 FIRST 4 DIGIT: TYPE OF CABLE(D1 TO D4)
D3 7
D4 8 FOR EXAMPLE 2000-2XFY(T),
3078-YWY(P)-HRPVC
D11 4 11TH AND 12TH DIGIT :UP TO 10 MM2, 41- STRANDED & 49- SOLID
D12 1 ABOVE 10 MM2, 49- STRANDED & OTHERS NON STRANDED
PLAN
O.C. NO: P2020187
TYPE:CP
RAW MATERIAL
INSULATION PROCESS
TYPE C INSULATION
NOMINAL THICKNESS: 1 mm
CORE DIAMETER:
AREA = 0.7850 X d2
4 = 0.7850 X d2
D1 = 2.25mm
CORE DIAMETER AFTER PVC INSULATION (D2) = 2.25 + 2 X 1
D2 = 4.25mm
FOR 0.987 KMS = 19.99 X 0.98 7
= 19.737 KG
FOR 4C = 19.737 X 4 = 78.950 KGS
AREA OF INSULATION = 0.7850X ( D22 - D12 )
= 0.7850 X (4.252- 2.252)
= 14.49 mm2
MASS OF PVC = AREA X DENSITY OF
MATERIAL(TYPEC)
= 14.49 X 1.38
= 19.99 KG/KM
FOR 0.987 KMS = 19.99 X 0.98 7 = 19.737 KG
FOR 4C = 19.737 X 4 = 78.950 KGS
= 15.130+ 2 X 1.48
D6 =18.09 mm
AREA OF O/SH = 0.7850 X (D62 – D52)
= 0.7850X (18.092- 15.1302)
= 77.189 mm2
• 1)BARREL
• 2)FLANGE
SUMMARY
RM REQ
SR NO. PROCESS M/C NAME RM ( KGS)
STRANDING
2 PROCESS 6+1 TUBLAR
INSULATION 45 MM
3 PROCESS EXTRUDER HRPVC (TYPE-C) 78.95
POLYESTER
4 LAID UP PROCESS 6+1 TUBLAR TAPE
INNER SHEATH 90 MM
5 PROCESS EXTRUDER ST-2 16.69
42 BOBBIN
ARMOURING ARMOURING
6 PROCESS MACHINE G.S.ROUND WIRE 272.722
OUTER SHEATHING 90 MM
7 PROCESS EXTRUDER ST-2 321.86
PROCESS FLOW CHART
PRODUCTION DEPARTMENT
WIRE DRAWING
• DEFINITION:
• WIRE DRAWING IS A METAL WORKING
PROCESS USED TO REDUCE THE DIAMETER OF A WIRE BY
PULLING THE WIRE THROUGH A SINGLE OR SERIES OF
DRAWING DIES.
• DIE MATERIALS:
HIGH SPEED STEEL
TUNGSTEN CARBIDE
DIAMOND
MATERIAL FOR WIRE DRAWING:
ALUMINUM(Ø 9.5mm)
1. DRAWMET :
PERFORMANCE BENEFITS:
EXCELLENT COOLING ABILITY
SUPERIOR WETTABILITY
LESS WIRE BREAKAGE
ANNEALING PROCESS:
• ANNEALING IS A PROCESS IN WHICH WIRE DRAWING
MATERIAL IS HEATED TO A TEMP. AROUND 550-6500C AND
THEN COOLED DOWN BY MEANS OF COOLANT.
BENEFITS OF ANNEALING:
ELONGATION STRENGTH INCREASES
BETTER FLEXIBILITY
TRANSFORMER
DANCER
TYPES OF WIRE DRAWING MACHINE
SR. NO. NAME OF MACHINE DIAMETER AREA
REDUCTION(MM) REDUCTION IN(%)
MAIN
MOTOR
DAN DAN
RAW WIRE TAKE-
- ANNEALING -
MATE DRAWING UP
CER CHAMBER CER
-RIAL CHAMBER
-1 -2
MAIN MOTOR
SPECIFICATION:
160 KW, 270 AMP, 1488
RPM,PF=0.86
CONDUCTOR
CONDUCTOR IS A SET OF WIRES BUNCHED IN A DIFFERENT
SHAPES. CURRENT RATING DEPENDS ON CONDUCTOR AREA.
AND IT IS DONE BY STRANDING PROCESS.
TYPES OF STRANDING
SECTOR SHAPE
COMPACT CIRCULAR(16 – 1000 MM2)
CIRCULAR(UP TO 10MM2)
CLASS OF CONDUCTOR
CLASS 1(SOLID)
CLASS 2(STRANDED)
AS PER IS MIN NUMBER OF WIRES ARE REQUIERED
CLASS 5(FLEXIBLE)
AS PER IS MAX. WIRE DIA IS MAINTAINED
C/S AREA NO.OF WIRES/WIRE DIAMETER
SOLID STRANDNED
(CLASS-1) (CLASS-2)
1 6+1(TUBLAR) 4-50
2 19 BOBIN 50-150
3 37 BOBIN 70-300
4 61 BOBIN 95-630
LINE DIAGRAM OF 19 BOBIN STRANDING MACHINE
=25.23 MPM
MACHINE HOUR RATE = 25.23 X 60 = 1514 m/hr = 1.51 km/hr
IN 8 HRS SHIFT : 1.51 X 8 = 12 KMS/SHIFT
ACTUAL PRODUCTION = 5 KMS/SHIFT
D.C RESISTANCE MUST BE MAINTAINED AS PER “IS”
TYPES:
Pressure extrusion
Sleeve/tube/vaccum extrusion
TYPES OF RAW MATERIAL
PVC COMPOUND
TYPE A(GENERAL PURPOSE INSULATION FOR 70˚C)
TYPE C(HEAT RESISTANCE INSULATION FOR 85˚C)
XLPE(SIOPLAS)(85-90˚C)
CURING OF XLPE:
CURING IS NECESSARY FOR PROPER CROSS LINKING .
FOR CURING PUPOSE INULATED CONDUCTOR IS HEATED FOR 4
TO 5 HR. AT 90˚ C.
FOR CHEKING OF PROPER CURING OF XLPE HOT SET TEST IS
DONE.
THICKNESS OF INSULATION IS MAINTAINED AS PER IS.
FLOWCHART
Spark
Pay-off Cooling trough Tracker voltage
tester
extruder
Printer
Take-up Caterpillar
150MM EXTRUDER
Tip
Clamp Gearbox
Clamp
Heater
Z-6(Metering zone) Z-4,Z-3,Z-2(Melting zone) Z-1(feeding zone)
Material flow
Ø=230MM PULLEY Ø=300MM
PULLEY
MOTOR
REDUCTION
GEAR,
¡=16.67
INSULATION INNERSHEATH
MACHINE AREA MACHINE AREA
45mm extruder -I 1TO 4
90mm extruder 1 TO 70
45mm extruder-II 1 TO 6
60mm extruder 2.5 TO 70 80mm extruder 1 TO 50
120mm extruder 35 TO 630 150mm extruder 16 above
OUTERSHEATH
MACHINE AREA
90mm extruder 1 TO 70
80mm extruder 1 TO 50
150mm extruder 16 AND ABOVE
INSULATION
INSULATION TYPE TYPE OF OUTER
SHEATH
0
TYPE-A(700C) ST-1(70 C)
TYPE- C(850C) ST-2(900C)
XLPE(900C) ST-2(900C)
Core sequence
Direction of lay & lay length.
Width & thickness of tape
Overlapping ratio of tape
Use of PVC fillers
LAID UP MACHINE
SR.NO. MACINE AREA CORE
1 4+1 6-50 2 TO 5
2 3+1 70-630 2 TO 4
3 DRUM 16-185 2 TO 4
TWISTER
4 24 BOBIN 1.5-2.5 2 TO 61
CATERPIL
RDH TPH BINDER TAKE-UP
LAR
37KW/50HP,
1440RPM,70AMP.,415V
6+1 TUBLAR
45KW SLIP-RING
MOTOR, 415V,1500RPM
ARMOURING
THE ARMOUR PROTECTS POWER CABLE AGAINST MECHANICAL DAMAGE
OR STRESS & ALSO USED FOR EARTHING PURPOSE.
TYPES OF ARMOURING:
FLAT STRIP ARMOURING(G.S AND ALUMINUM)
ROUND WIRE ARMOURING(G.S,CU)
CU TAPES (IN SPECIAL CASE)
24 42
PAY-OFF BOBIN BOBIN DIE TAPING
CAGE CAGE HOLDER HEAD
AT 200C.
HOT DEFORMATION :
SIGNIFICANT:
DURING LAYING CABLES ARE PULLED FROM ONE END ALONG TRENCHES
CABLESIN MINE SHAFT BRIDGES VERTICAL RUNS ETC CABLE BY VIRTUE OF
THEIR SUPPORTING METHODS ARE SUBJECTED TO PERMANENT STRESS
MATERIAL HAS ADEQUATE STRENGTH AND CAPACITY TO GET ELONGATED.
CALCULATION :
ELONGATION AT BREAK=
ORDER QUOTATION
P.O(PURCHASE ORDER)
MISCELLANEOUS
MATERIAL REJECTION
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