COPPER AND ALUMINIUM WIRE & CABLE UNIT

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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.

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Description

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
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
MARKET POSITION
FINOLEX CABLES
HAVELLS INDIA
POLYCAB
STERLITE TECHNOLOGIES
KIE INDUSTRIES
MARKET GROWTH
OVERVIEW OF WIRES AND CABLE INDUSTRY IN INDIA
FEW PROFITABLE BUSINESS IDEAS IN WIRE CABLE MANUFACTURINGINDUSTRY
POWER CABLES
STITCHING WIRE
PVC ELECTRIC WIRES & CABLES
FIBER OPTICAL CABLES
POWER CABLE
PVC & XLPE CABLES
R-F COAXIAL CABLE
ALUMINIUM WIRE & CABLES
LT CABLE
LV CONTROL & POWER CABLES, MV CABLES
ALUMINIUM WIRE DRAWING WIRE MESH PLANT
WIRE DRAWING LUBRICANTS
COPPER WIRE DRAWING (FROM HIGHER SIZE TO VERY THIN SIZE USED IN ELECTRICAL CABLES)
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:
SPECIFIC FACTORS
6. TRANSPORTATION:
A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
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 COPPER WIRE AND CABLE
SUPPLIERS OF ALUMINIUM WIRE AND CABLE
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF COOPER WIRE ROD
SUPPLIERS OF ALUMINUM WIRE RODS
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)

Additional information

Plant Capacity

3 MT/Day
Land & Building

(6000 sq.mt.)
Plant & Machinery

Rs. 2.55 Cr
Rate of Return

33%
Break Even Point

51%

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