COPPER AND ALUMINIUM WIRE AND CABLE MANUFACTURING UNIT

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.

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.

INTRODUCTION
TYPES OF ELECTRICAL WIRES
THERE ARE TWO MAIN TYPES OF WIRES: SOLID OR STRANDED.
COPPER WIRE
PROPERTIES
PROPERTIES OF COPPER WIRE
ALUMINIUM WIRE
PROPERTIES
ELECTRICAL CABLE
PROPERTY
APPLICATION
ADVANTAGES
ADVANTAGES OF PVC CABLES
SOME OF THE MAJOR ADVANTAGES OF PVC CABLES
CONSTRUCTION
CONDUCTOR
INSULATION
THE FOLLOWING COLOUR CODE IS USED FOR IDENTIFICATION:
LAYING UP
INNERSHEATH
ARMOURING
OUTERSHEATH
USES AND APPLICATION
APPLICATIONS
B.I.S. SPECIFICATION
MARKET POSITION
CURRENT STATUS
PRODUCT SECTORS
GROWTH DRIVERS
GROWTH AREAS
CHALLENGES
THE FUTURE
GOVERNMENT INITIATIVE
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 ARMOURED ALUMINIUM CABLE
TOTAL VALUE & VOLUME OF EXPORTS IN INDIA
TOP SUPPLIERS
TOP PORTS OF DISCHARGE
EXPORT DATA OF SINGLE ALUMINIUM CABLE
TOTAL VALUE & VOLUME OF EXPORTS IN INDIA
TOP SUPPLIERS
TOP PORTS OF DISCHARGE
IMPORT DATA OF ALUMINIUM WIRE
TOTAL VALUE & VOLUME OF IMPORTS IN INDIA
TOP SUPPLIERS
TOP PORTS OF DISCHARGE
EXPORT DATA OF PVC COPPER FLEXIBLE
TOTAL VALUE & VOLUME OF EXPORTS IN INDIA
TOP SUPPLIERS
TOP PORTS OF DISCHARGE
IMPORT DATA OF INSULATED COPPER CABLE
TOTAL VALUE & VOLUME OF IMPORTS IN INDIA
TOP SUPPLIERS
TOP PORTS OF DISCHARGE
IMPORT DATA OF PVC COPPER WIRE
TOTAL VALUE & VOLUME OF IMPORTS IN INDIA
TOP SUPPLIERS
TOP PORTS OF DISCHARGE
MANUFACTURERS/SUPPLIERS OF COPPER WIRE AND CABLE
MANUFACTURERS/SUPPLIERS OF ALUMINIUM WIRE AND CABLE
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    101
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
PLANT LAYOUT
SUPPLIERS OF RAW MATERIALS
COPPER WIRE ROD
ALUMINUM WIRE RODS
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:

1.      COST OF PLANT ECONOMICS
2.      LAND & BUILDING
3.      PLANT AND MACHINERY
4.      FIXED CAPITAL INVESTMENT
5.      RAW MATERIAL
6.      SALARY AND WAGES
7.      UTILITIES AND OVERHEADS
8.      TOTAL WORKING CAPITAL
9.      COST OF PRODUCTION
10.      PROFITABILITY ANALYSIS
11.      BREAK EVEN POINT
12.      RESOURCES OF FINANCE
13.      INTEREST CHART
14.      DEPRECIATION CHART
15.      CASH FLOW STATEMENT
16.      PROJECTED BALANCE SHEET