ASSIGNMENT OF

PRODUCTION ENGINEERING - I: -

TOPIC: ELECTRIC CABLES

PARTICIPANT’S NAMES AND ROLL NUMBERS:

1. SYED AHMER IQBAL … ME-18141
2. MUHAMMAD SHAHRUKH BIN ZAID … ME-18142
3. MUHAMMAD ALIYAN MUJAHID … ME-18155
4. SYED ABDUL MOIZ HAIDER … ME-18156
5. MUHAMMAD ABDULLAH NADEEM … ME-18157

SEC: D

SUBMITTED TO: MR. HASSAN LIAQUAT

Introduction to Electric Cables: -
An Electric Power Cables are factory assembly of two or more conductors having an overall
covering. Several types of cables are manufactured for specific applications. A cable has one
or more insulated conductors usually covered with a protective jacket. Cable types used in
commercial and industrial wiring applications include armored, metal-clad, nonmetallic-
sheathed, mineral-insulated, tray cable, service-entrance, underground feeder and branch-
circuit, low-voltage, and medium-voltage.

Components of Electrical Cables

All electrical cables consist of at least two conducting wires and an outer protective jacket.
For medium to high power cables that carry high voltages, the conducting wires within the
outer protective jacket may individually be enclosed in insulating sheaths. Electrical
conductors are commonly made of copper. Synthetic polymers make the outer jacket and
protective, insulating material.
Construction of Cable
The power cable mainly consists of three main components, namely, conductor, dielectric,
and sheath. The conductor in the cable provides the conducting path for the current. The
insulation or dielectric withstands the service voltage and isolates the conductor with other
objects. The sheath does not allow the moistures to enter and protects the cables from all
external influences like chemical or electrochemical attack, fire, etc. The main components
of electrical power cables are explained below in details.

Conductor
Coppers and aluminum wires are used as a conductor material in cables because of their
high electrical conductivity. Solid or number of bare wires made of either copper or
aluminum are used to make a power cable.
For a conductor having more than three wires, the wire is arranged around a center wire
such that there are six in the first layer, twelve in the second, eighteen in the third, and so
on. The number of wires in the conductors are 7, 19, 37, 61, 91, etc., The size of the
conductor is represented by 7/A, 19/B, 37/C, etc., in which first figures represent the
number of strands and the second figure A, B, C, etc., represents the diameters in cm or mm
of the individual wire of the conductors.
Insulation
The most commonly used dielectric in power cables is impregnated paper, butyl rubber,
polyvinyl chloride cable, polyethylene, cross-linked polyethylene. Paper insulated cables are
mostly preferred because their current carrying capacity is high, generally reliable and
having a long life. The dielectric compound used for the cable should have following
properties.
The insulator must have high insulation resistance.
It should have high dielectric strength so that it does not allow the leakage current to pass
through it.
The material must have good mechanical strength.
The dielectric material should be capable of operating at high temperature.
It should have low thermal resistance.
It should have a low power factor.
The cables used for submarine and damp soil should use synthetic dielectrics like polyvinyl
chloride, polyethylene, etc. These materials are comparatively lighter and have
nonmigratory dielectric. Also, such type of dielectric material has good dielectric strength,
low power loss, and low thermal resistance.
Inner Sheath
It is used for protecting the cable from moistures which would affect the insulation. Cable
sheath is made up of lead alloy, and these strengths withstand the internal pressures of the
pressurized cables. The material used for inner sheath should be nonmagnetic material.
The aluminum sheath is also used in a power cable because it is cheaper, smaller in weight
and high mechanical strength than the lead sheath. In oil-filled cables and telephone,
cables corrugated seamless aluminum sheath is used because it has better-bending
properties, reduced thickness, and lesser weight.
Protective Covering
Lead sheath cables when directly laid down on the ground are damaged by corrosion and
electrolyte. For protecting the cables against corrosion layers of fibrous material like paper,
hessian, etc., or polyvinyl chloride is used. Layers of fibrous material spread with the
waterproof compound to the outside of the electrical cable are called serving.
Armoring:
Armoring is the process in which layers of galvanized steel wires or two layers of metal tape
are applied over sheath for protecting it from mechanical damage. The steel wires are
normally used for armoring because it has high longitudinal strength. Armoring is also used
for earthing the cable. When the fault occurs in the cable (due to insulation failure) the fault
current flows through the armor and get earthed.
Over Sheath
It gives the mechanical strength to the cables. It protects the cable from overall damage like
moisture, corrosion, dirt, dust, etc. The thermosetting or thermoplastic material is used for

making over the sheath.

Properties
Electric Properties
Dielectric strength, Insulation resistance, Insulation power factor, charging current, Arc
resistance, Tracking susceptibility
Mechanical Properties
Toughness and flexibility, Tensile elongation and crushing strength, Resistance to abrasion
and moisture, brittleness.
Chemical Properties
Moisture absorption, Resistance to oil gas acid and alkali, Stability when exposed to sunlight
ozone and flames.
Thermal Properties
Expansion and contraction, Softening and flow temperature, compatibility and operating
ambient or emergency overload and short circuit conditions
Electrical Cable and Wire Color Markings:
Non-metallic 120-volt and 240-volt electrical cable come in two main parts: the outer plastic
sheathing (or jacket) and the inner, color-coded wires.
But looking deeper, the color of the wires inside of the sheathing reveals that different
colored wires serve different purposes. The National Electrical Code (NEC) says that white or
gray must be used for neutral conductors and that bare copper or green wires must be used
as ground wires. Beyond that are general, industry-accepted rules about wire color that
indicate their purpose.
HISTORY AND EVOLUTION OF CABLES
The term cable originally referred to a nautical line of specific length where
multiple ropes are combined to produce a strong thick line that was used to anchor large
ships. As electric technology developed, people changed from using bare copper wire to
using groupings of wires and various sheathing and shackling methods that resembled the
mechanical cabling so the term was adopted for electrical wiring. In the 19th century and
early 20th century, electrical cable was often insulated using cloth, rubber or paper. Plastic
materials are generally used today, except for high-reliability power cables. The term has
also come to be associated with communications because of its use in electrical
communications.
The first power distribution system developed by Thomas Edison in 1882 in New York City
used copper rods, wrapped in jute and placed in rigid pipes filled with
a bituminous compound. Although vulcanized rubber had been patented by Charles
Goodyear in 1844, it was not applied to cable insulation until the 1880s, when it was used
for lighting circuits. Rubber-insulated cable was used for 11,000-volt circuits in 1897
installed for the Niagara Falls power project.
Mass-impregnated paper-insulated medium voltage cables were commercially practical by
1895. During World War II several varieties of synthetic rubber and polyethylene insulation
were applied to cables.

By the 1890’s mass impregnated paper insulation was being used on cables and voltages as
high as 10kV. In 1906 armored cables were introduced which had flexible sheathing and two
cloth covered, rubber insulated conductors. In the 1930’s the first trials with PVC
installation were being made in Germany and by the end of the second world war there
were significant varieties of synthetic rubbers and polyethylene. By the 1950’s PVC was
commercially viable and replaced rubber cables in many areas particularly in domestic
wiring, aluminum was also starting to be used widely as an alternative conductor
the 1970’s heralded XLPE insulations replacing paper insulated cables in medium
voltage applications. In the 1980’s optical fiber was being introduced in overhead lines for
data transmission and condition monitoring, and further use of XLPE in high voltage
transmission lines between 66 and 240kV. Also, high temperature super conductivity
materials were discovered. PVC alternatives (LSZH cables) which were safer in fires were
being developed in response to a number of tragic public fires which demonstrated the
dangers of smoke and toxic gases from various materials including PVC’s. By
the 1990’s polymers were being extended to use in EHV, extra high voltage, applications and
the use of optical fibers in overhead lines was becoming widespread. And by now optical
fiber cables are being used frequently due to its strength.

Modern Applications
Electrical cables are used to connect two or more devices, enabling the transfer of electrical
signals or power from one device to the other. Cables are used for a wide range of purposes,
and each must be tailored for that purpose. Cables are used extensively in electronic devices
for power and signal circuits. Long-distance communication takes place over undersea
cables. Power cables are used for bulk transmission of alternating and direct current power,
especially using high-voltage cable. Electrical cables are extensively used in building
wiring for lighting, power and control circuits permanently installed in buildings. Since all
the circuit conductors required can be installed in a cable at one time, installation labor is
saved compared to certain other wiring methods.
Physically, an electrical cable is an assembly consisting of one or more conductors with their
own insulations and optional screens, individual covering(s), assembly protection and
protective covering(s). Electrical cables may be made more flexible by stranding the wires.
In this process, smaller individual wires are twisted or braided together to produce larger
wires that are more flexible than solid wires of similar size. Bunching small wires before
concentric stranding adds the most flexibility. Copper wires in a cable may be bare, or they
may be plated with a thin layer of another metal, most often tin but
sometimes gold, silver or some other material. Tin, gold, and silver are much less prone
to oxidation than copper, which may lengthen wire life, and makes soldering easier. Tinning
is also used to provide lubrication between strands. Tinning was used to help removal of
rubber insulation.
Cables can be securely fastened and organized, such as by using trucking, cable trays, cable
ties or cable lacing. Continuous-flex or flexible cables used in moving applications
within cable carriers can be secured using strain relief devices or cable ties.

Electrical cable types

Following are some types of cables
Communications cable
These cables are used in a wide variety of applications, including
recording studios, data transmission, radio transmitters, intercoms,
electronic circuits, and in applications where RF shielding is
needed. Communication Cables are electrical cables used to send
information signals.
MATERIALS UESED IN MANUFACTURING:
There are many varieties of metals used for cabling such as pure
copper, clad copper and aluminum wire.
Cat5 cable consists of four pair cables for carrying signals. Mostly,
the cable is used in computers for transmitting networks such as
Ethernet. However, other signals such as telephony and video can
be carried using the cables. Normally, punch down blocks and modular connectors are
adopted to connect the cables. Cat5 has been advanced by the emergence of Cat5e
technology that supports Ethernet, Fast Ethernet and Gigabit Ethernet (10/1000). The “e” in
Cat5e refers to completely backward compatibility.

Cat5e and Cat5 cables are made out of a copper material within a sheath, generally PVC.
There are various types of Category Cable, for example those for use and rated for ceilings,
for walls, outdoor and indoor. Cat5 and Cat5e are no exception.
Direct-buried cable
Cable that is rated for direct burial applications is designed to be
able to be buried directly beneath the ground without any added
protection, piping, or sheathing. Direct burial cable is built to
tolerate heat, moisture, and other hazards that present
themselves when cable is buried underground.
Types of Underground Electric Transmission Cables
There are two main types of underground transmission lines
currently in use. One type is
Constructed in a pipe with fluid or gas pumped or circulated through and around the cable
in order to manage heat and insulate the cables.
The other type is a solid dielectric cable which requires no fluids or gas and is a more recent
technological advancement. The common types of underground
cable construction includes:
High-pressure, fluid-filled pipe (HPFF)
High-pressure, gas-filled pipe (HPGF)
Self-contained fluid-filled (SCFF)
Solid cable, cross-linked polyethylene (XLPE)
MATERIALS UESED IN MANUFACTURING:
For underground cable systems, many technical issues need to be considered. Among these,
limiting moisture ingress for all cable types is important. Generally, ethylene propylene
rubber-insulated cable and cross-linked polyethylene-based cable (XLPE distribution cable)
with tree-retardant additives are considered. (treelike growths, consisting of nonsolid or
carbonized microchannels that can occur at stress enhancements such as protrusions,
contaminants, voids, or water trees subjected to electrical stress for extended time periods).
At the site of an electrical tree the insulation is damaged irreversibly, partial discharge may
be present, and complete insulation breakdown may be only a question of time. The cross-
section of deep-sea fiber-optic cable is given in Fig. 2.10. Table 2.1 shows the various
materials used for cables. They provide insulation and jacketing for more than 30,000
different types of wire and cable products.
Heliax cable
Cables used in industrial robots are periodically exposed to external loading which includes
torsion and bending. The task of the cables is to supply electricity. Under mechanical loads,
the cable has a limited usage period due to internal failures caused by the deformation,
fatigue and wear of internal components.
MATERIALS UESED IN MANUFACTURING:
A typical cable consists of a jacket, shield, tape, fillers and conductors. The jacket serves
several purposes. It is the main protection of the vital parts of the cable from external loads
and environmental effects. The cross-sectional layout is preserved mainly by the jacket, i.e.
the internal organization of the components remains unchanged during deformation of the
cable.
Conductors consist of copper wires bundled to form a helical structure and are wrapped
with insulation material. This forms a helix-in-helix which is the characteristic structure of
the electrical cable and it is referred to as a second level helical structure in this work. Lay
angle and helical radius are again defined for center line of the wire.
sheathed cable
there are two types of sheathed cables
Non-metallic sheathed cable (or nonmetallic building wire, NM, NM-B)
Metallic sheathed cable (or armored cable, AC, or BX)
MATERIALS UESED IN MANUFACTURING:
Conductor
Usually stranded copper (Cu) or aluminum (Al). Copper is denier and heavier, but more
conductive than aluminum. Electrically equivalent aluminum conductors have a cross-
sectional area approximately 1.6 times larger than copper, but are half the weight (which
may save on material cost). Annealing – is the process of gradually heating and cooling the
conductor material to make it more malleable and less brittle.
Coating – surface coating (e.g. tin, nickel, silver, lead alloy) of copper conductors is common
to prevent the insulation from attacking or adhering to the copper conductor and prevents
deterioration of copper at high temperatures. Tin coatings were used in the past to protect
against corrosion from rubber insulation, which contained traces of the sulfur used in the
vulcanizing process
Insulation
Commonly thermoplastic (e.g. PVC) or thermosetting (e.g. EPR, XLPE) type materials.
Mineral insulation is sometimes used, but the construction of MI cables is entirely different
to normal plastic / rubber insulated cables. Typically, a thermosetting (e.g. EPR, XLPE) or
paper/lead insulation for cables under 22kV. Paper-based insulation in combination with oil
or gas-filled cables are generally used for higher voltages.
Twinax cable
Twinaxial cabling, or "Twinax", is a type of cable similar to coaxial cable, but with two inner
conductors instead of one. Due to cost efficiency it is becoming common in modern (2013)
very-short-range high-speed differential signaling applications.
MATERIALS UESED IN MANUFACTURING:
Both Twinax and Triax connectors are constructed from high-quality materials, including
nickel-plated brass bodies and be- ryllium-copper outer and center conductors, with push
on and threaded versions available.
Twin-lead
This type of cable is a flat two-wire line. It is commonly called a 300 Ω line because the line
has an impedance of 300 Ω. It is often used as a transmission line between an antenna and a
receiver (e.g., TV and radio). These cables are stranded to lower skin effects.
MATERIALS UESED IN MANUFACTURING
Twin-lead cable is a two-conductor flat cable used as a balanced transmission line to carry
radio frequency (RF) signals. It is constructed of two stranded copper or copper-clad steel
wires, held a precise distance apart by a plastic (usually polyethylene) ribbon
Twin-Lead Cable is a flat cable comprises of two conducting wires each separated by
insulating material of plastic or polyethylene. The name twin-
lead is given to the wire because of copper leads inside the
fence are equally alike using Copper or copper clad steel wires
as the conductor of this cable. The twin-lead cable is used for
the transmission of radio frequency (RF) signals, and the
spacing in between them is of paramount importance. Because
in the transfer of the radio signal, it is the distant spacing that
keeps the sign moving through without any back reflection of
the message.
Characteristics of Twin-Lead Cable
1) The wire diameter and its spacing dictate the
impedance of the twin-lead cable.
2) The most commonly used twin-lead cable is 300
ohms, using the wire of 20 or 22 gauge and about 7.5
inches apart.
3) Impedance matches correctly of the 300 ohms’
twin-lead cable with the folded dipole antenna.
4) Twin-lead cable has the lowest signal losses than
coaxial cable if installed under similar conditions.
5) But twin-lead is more vulnerable to It is also more prone to get damaged by the
weather and by its established environment.
Coaxial cable
used for radio frequency signals, for example in cable
television distribution systems.
MATERIALS UESED IN MANUFACTURING:
Coaxial cable conducts electrical signal using an inner
conductor (usually a solid copper, stranded copper or
copper plated steel wire) surrounded by an insulating
layer and all enclosed by a shield, typically one to four
layers of woven metallic braid and metallic tape
Properties
The source and load impedances are chosen to match the impedance of the cable to ensure
maximum power transfer and minimum standing wave ratio. Other important properties of
coaxial cable include attenuation as a function of frequency, voltage handling capability, and
shield quality.
Twisted pair
Consists of two interwound insulated wires. It resembles a paired cable, except that the
paired wires are twisted
Properties:
A twisted pair consists of two insulated conductor twisted together
in the shape of a spiral as shown in figure. It can be shielded or
unshielded. The unshielded twisted pair cables are generally very
cheap and easy to install. But they are badly affected by the
electromagnetic noise interference
Twisted-pair cable is a type of cabling that is used for telephone
communications and most modern Ethernet networks.
The following summarizes the features of UTP cable:
Speed and throughput—10 to 1000 Mbps.
Average cost per node—Least expensive.
Media and connector size—Small.
Maximum cable length—100 m (short)
Multicore cable (consist of more than one wire and is covered by cable jacket)
A multicore cable is a type of electrical cable that combines multiple signals or power feeds
into a single jacketed cable. The term is normally only used in relation to a cable that has
more cores than commonly encountered. Not all cables with multiple insulated conductors
are called multicore cables – the core in multicore refers to the number of usable
connections made, not the number of conductors or wires. In most cases, a "usable
connection" requires multiple conductors, such as the positive and negative conductors
used for DC power.
MATERIALS UESED IN MANUFACTURING:
The conductors of multicore cables are generally made up of copper and aluminum alloys
Construction: -
By definition, multicore cables have an outer sheath which surrounds all of the inner
conductors. This is usually in the form of an extruded PVC or cross-linked polyethylene
jacket, often combined with an aluminum sheath under the surface for electromagnetic
shielding.
In further types we have
Paired cable – Composed of two individually insulated conductors that are usually used in
DC or low-frequency AC applications

Ribbon cable – Useful when many wires are required. This type of cable can easily flex, and
It is designed to handle low-level voltages.
Construction:
The wire is usually stranded copper wire, usually either 0.32, 0.20, or 0.13 mm2 (22, 24, or
26 AWG). Finer and coarser pitch cables are also available. For instance, the high-speed ATA
interface cable used for computer hard disk interfaces ULTRA-ATA has 0.025-inch (0.64-mm)
pitch
Portable cord– Flexible cable for AC power in portable applications
Shielded cable – Used for sensitive electronic circuits or to provide protection in high-
voltage applications
Construction: -
Internal part of most of these cables are made by means of copper and aluminum (alloys)
coiled up in different arrangement.

MANUFACTURING PROCESS

A manufacturing process is a designed procedure that results in physical and/or

chemical changes to a starting work material with the intention of increasing the value of
that material.

MANUFACTURING PROCESS OF ELECTRIC CABLES

STEP 1: WIRE DRAWING:

Wire drawing is a metalworking process used to reduce the cross-section of a wire by pulling
a wire through a single, or series of, drawing die. The wire drawing process
is quite simple in concept. The wire is prepared by shrinking the beginning of it, by
hammering, filing, rolling or swaging, so that it will fit through the die; the wire is then
pulled through the die. As the wire is pulled through the die, its volume remains the same
its length increases and diameter decreases. The area reduction in small wires is generally
15–25% and in larger wires is 20–45%. This can be done on a small scale with a draw plate
or on a large commercial scale using automated machinery.

Our aim is to acquire metal (usually copper or aluminum) wires that fit with AWG (American
Wire Gauge). The method is to pull the copper or aluminum rod through a series of
synthetic diamond dies, which gradually decrease in size, on the draw bench. And this is
processing with a lubricating and cooling system that increased the life of the dies and
prevents the wire from overheating.

STEP 2: ANNEALING:

In metallurgy and materials science, annealing is a process of heating metal and alloy to
appropriate temperature for a certain time period and then slowly cooling (generally with
furnace cooling). The purpose of annealing is:

to remove hardness of metal, improve plasticity and facilitate machining and cold
deformation process;
Eliminate internal stress and process hardening to prevent deformation and cracking;
To improve the performance of metal or to prepare for quenching.
It involves heating a material above its recrystallization temperature, maintaining a suitable
temperature for a suitable amount of time, and then allow slow cooling. For many alloys,
including carbon steel, the crystal grain size and phase composition, which ultimately
determine the material properties, are dependent on the heating rate and cooling rate. Hot
working or cold working after the annealing process alter the metal structure, so
further heat treatments may be used to achieve the properties required. With knowledge of
the composition and phase diagram, heat treatment can be used to adjust from harder and
more brittle to softer and more ductile.

During the drawing process, we apply tremendous pressure on metal rod to form a thinner
wire. Thus, the wire we get is extremely brittle and can easily be fractured if flexed. The
finished wire must be flexible, so in this step we’re going to soften, or to anneal the wire.
STEP 3: TWISTING AND STRANDING:
As mentioned above, multiple wires often get stranded. That’s because given the same
cross-sectional area, stranded wire has better flexibility and electrical performance than
single wire.
In this step, two or more wires of the same gauge are twisted or stranded together using a
proprietary formula to determine twist length.

STRANDED WIRE TWISTING MACHINE

STEP 4: EXTRUSION:
Extrusion is a process used to create objects of a fixed cross-sectional profile. A material is
pushed through a die of the desired cross-section. The two main advantages of this process
over other manufacturing processes are its ability to create very complex cross-sections,
and to work materials that are brittle, because the material only
encounters compressive and shear stresses. It also forms parts with an excellent surface
finish.
Extrusion may be continuous (theoretically producing indefinitely long material) or semi-
continuous (producing many pieces). The extrusion process can be done with the material
hot or cold. Commonly extruded materials include metals, polymers, ceramics, concrete,
modelling clay and foodstuffs. The products of extrusion are generally called "extrudates".
The process begins by heating the stock material (for hot or warm extrusion). It is then
loaded into the container in the press. A dummy block is placed behind it where the ram
then presses on the material to push it out of the die. Afterward the extrusion is stretched
in order to straighten it. If better properties are required then it may be heat treated or cold
worked.
The extrusion ratio is defined as the starting cross-sectional area divided by the cross-
sectional area of the final extrusion. One of the main advantages of the extrusion process is
that this ratio can be very large while still producing quality parts.
Cross-head extrusion process is widely used to coat wires and cables with a polymer-based
insulation.
In the manufacturing of electric cables forth step is extrusion: The wire, now soft and
flexible, is passed through an extruder, where the coating of plastic or other insulating
material is applied.
Materials are poured into the rear part of the extruder, and are pushed forward while
heated into melt. Exiting the extruder, the coated wire passes through another cooling
system and is coiled on reels.

STEP 5: CABLING:

The basic component of cable is now prepared. Next, we need to assemble the cable
according to different utilities. This process is done in a cabling station.

For the electrical and electronic cables in daily use, we just need to wrap up one or more
strands of wires, together with interference-preventing layer if needed, into the protection
jacket. In order to have a better forming degree, we often use filler to ensure the finished
cable in a shape of round.

For power cable and other cables that need to be buried underground, there are more
protective measures:
bedding/inner sheath:
usually a plastic layer to keep the inner wires together and prepare the ‘bed’ for steel
armor.

steel armor:
A steel layer used to sustain the pressure and prevent pests underground.

outer sheath:
usually a layer made from the same material as inner sheath, applied over the armor for
overall mechanical, weather, chemical and electrical protection
Finished cables and wired are tested for electrical parameters and defects. The final cables
are cut to standard lengths as per specification and packed on spools, wooden drums etc. or
packed into cable coils.

SCHEMATIC DIAGRAM:

WIRE DRAWING
 ANNEALING

TWISTING AND
STRANDING

EXTRUSION

CABLING

FINAL TESTING

FINAL PRODUCT

Product facilities of electric cables in Pakistan

Following are the product facilities of electric cables in Pakistan
Pioneer cables
ABOUT US
Being a Pioneer in the field of manufacturing High Tension Cables, the management decided
to choose a company theme line to reflect that achievement. Our motto was also inscribed
within our four walls as “Pioneer by Name, Pioneer by Deed”. Today, we feel that we have
to give credit to our extensive supply records consisting of more than any other unit in
Pakistan, an expert technical team, system of quality assurance and reliability; and a most
excellent reputation with our clients
MISSION
 To help conserve the country’s foreign exchange resources and keeping in view such
innovation and future requirements arising out of technological development in the field of
power cables, Pioneer Cables Limited was established at Hub Chowki in the District of
Lasbella, Balochistan, in Technical Collaboration with AEI of U.K. (a subsidiary of GEC) to
manufacture all sorts of power cables including Cross Linked Polyethylene Insulated Low
Tension/High Tension Cables for the first time in Pakistan in order to meet the demand and
to power the progress of the country. Pioneer Cables Limited manufactures Low & Medium
Voltage PVC Insulated Armored & Unarmored Power Cables, besides, XLPE Low & Medium
Voltage Cables alongside the XLPE High Voltage Cables. The Cable Plant is the most modern
and automated and is fully equipped with adequate testing facilities. It is managed by
skilled, highly qualified and experienced personnel trained abroad.
The Company is managed by Professional Managers in different fields. Almost all heads of
Technical/Manufacturing Departments have been trained in AEI Cables Ltd., plant at
Gravesend U.K
PRODUCT OVER VIEW
PVC INSULATED GENERAL WIRING
PVC Insulated Flexible & Control Cables are manufactured in accordance with BS-6004, BS-
6500 with a number of International Standards.
This products range is suitable for applications including measuring and control equipment
in fixed or flexible installations.

PVC INSULATED FLEXIBLE WIRING

Flexible Cable is also known as portable cord is a cable with multiple wires used in conductor
for functions requiring flexibility. The cord can be employed for power In a range of
applications for used in many commercial, industrial, and residential applications, including
appliances and extension cords.
The design and proper selection of a cable should take into account environmental
conditions, electrical, thermal and mechanical stresses that can be expected, as these all
have a bearing on its operating life. All Pioneer Cables, Flexible Cables are designed to suit
their application perfectly, thereby, ensuring a long trouble-free service life.
Flexible Cables are made up of conductors consisting of small, strands and either twisted or
bunched. These cables meet either Class-5 or Class-6 of BS-6360.

XLPE HIGH TENSION POWER CABLES ARMOURED & UNARMOURED

XLPE Insulated Power Cables are manufactured in accordance with IEC-60502-1 & IEC-
60502-2, as well as wide range of International Standards.
These cables can be used for power supply medium voltage (MV) applications. They are
available with Copper (Cu) or Aluminum (Al) conductors with PVC Sheathing.

LOW TENSION POWER CABLES ARMOURED & UNARMOURED

PVC Insulated Power Cables are manufactured for a voltage range of 1kV to 3.3kV in
accordance with BS-6360. They also comply with number of International Standards,
including IEC-60502-1.
These cables can be used in applications from power and auxiliary control, to power
networks. They are available with Copper (Cu) or Aluminum (Al) Conductors. Armored &
Unarmored Cables with PVC Sheathing.
OVERHEAD CONDUCTORS ALUMINIUM & COPPER
Aluminum (Al) Conductors also referred as All Aluminum Conductor (AAC), All Aluminum
Alloy Conductor (AAAC) and Aluminum Conductor Steel Reinforced are manufactured in
accordance with a number of British Standards and International Standards.
Hard Drawn Bare Copper (HDBC) Conductors are manufactured in accordance with a
number of British Standards and International Standards.
Fast cables
Since its inception in 1985, Fast Cables Limited
has emerged as Pakistan’s leading and most
trusted electrical cable manufacturer.
At Fast Cables quality is first priority combined
with superior customer service and affordability.
Our emphasis on quality has made Fast Cables one of the
most reliable brands in the Cable Industry of Pakistan and
the choice of leading electrical consultants, engineers and architects in the country.
The manufacturing plant in Lahore is equipped with state-of-the-art technology along with
an excellent quality assurance system. In addition to our current product portfolio, we also
manufacture electrical cables and conductors to cater to the specific needs of our valued
customers. We have served the cables needs of our customers from diverse sectors
including Building & Infrastructure, Oil & Gas, Telecommunication and many others.
PRODUCT OVER VIEW
Fast Cables’ MV cable manufacturing facility features latest technology at par with best
manufacturing facilities overseas. manufacturing plants in Lahore are equipped with state-
of-the-art technology along with excellent quality assurance systems. We are the pioneers
of CCV Line Technology & Aluminum Alloy Plant in Pakistan.
Key Features of CCV Line
Nitrogen generator plant for on line dry curing
Online touch free sag control system for best accuracy
Triple headed cross linking extruder
Sikora X ray for precision in online measuring

Advantages
More than 40 years product life
Insulation has no eccentricity
Cross-linking by use of Nitrogen gas guarantees excellent characteristics of insulation
Simultaneous extrusion of the inner and outer semi-conducting layers and insulation
prevents treeing and other irregularities
Uniformity of quality is maintained in all products as the manufacturing processes are
controlled by computer.
GM cables and pipes (pvt.) ltd.
Established in 1975 by late M. Jahangir Chaudhary as a small scale industry, Today GM
Cables & Pipes (Pvt) Ltd. stands as one of the most reputed, well known and well
established manufacturer of Cables, Pipes and Ducts in Pakistan. The plant is located at
Firozpur road , Lahore producing a distinguish range of electric cables , pipes and ducts.it is
well equipped with latest machinery and technology. Keeping in mind the international
standard, quality control and consistency.
PRODUCT OVER VIEW
GM production team at the plant analysis all the manufacturing orders to establish efficient
production of the orders.
GM utilizes best available raw materials to ensure supreme quality of products. Raw
materials are tested before using and any material not meeting with parameters are
rejected.
GM products are manufactured using modern of art machinery by skilled and efficient man
power.
Products are checked at regular phase of production to ensure compliant finished product.
GM products go through stringent testing to ensure compatibility with the applicable
standards and safe up to the mark performance after installation.

Pakistan cables limited

Pakistan Cables is the premier cable manufacturer and market leader in Pakistan. Since its
inception in 1953, Pakistan Cables has continuously strived to attain excellence
by maintaining quality standards par excellence which uses 99.99 percent pure Copper in
the manufacturing of wires and cables. Pakistan Cables is the only cable manufacturer with
a history of foreign affiliations with international cable manufacturers of stature. During
1952 till 1993 British Insulated Calendar Cable (BICC) and Pakistan Cables remained joint
venture partners. BICC was one of the world's leading cable companies of the world during
this period. During 2010-2017 General Cable, a Fortune 500 company remained a minority
shareholder in Pakistan Cables holding 24.6% of the company equity.
PRODUCT OVER VIEW

Cables wires
Whether you are investing in a home, constructing a commercial
building or setting up an industrial unit, choose wires and cables manufactured by Pakistan
Cables. Our wires and cables are manufactured using 99.99 percent pure copper, cable
grade PVC and rigorous quality tests. That way we help reduce your electricity bills through
efficient electricity consumption and ensure the safety of your loved ones. Our complete
range of wire & cable solutions conform to national and international standards. We
manufacture general wiring cables in the range of 250/750 Volts, conforming to BS:
6004:95.
Alumex
Alumex is the brand name of our business division that manufactures
aluminum sections and profiles for architectural construction and industrial applications.
ALUMEX® sections are extruded from prime quality
imported AA 6063 billets. This is the internationally
recommended grade for architectural and structural
applications. These sections are anodized on a fully
automated plant
Copper rod
Since 1996 we have been manufacturing
8mm Copper Rod that uses only LME registered “A” grade
copper cathodes. We are the only Pakistani manufacturer to
have a state of the art Up-cast plant, which produces High
Conductivity Oxygen Free Copper Rod used in wire manufacturing. This is a 99.99 percent
pure copper with minimum oxygen content, which achieves a 101% IACS conductivity.
Specific characteristics of High Conductivity Oxygen Free Copper Rod include: • high ductility
• high electrical and thermal conductivity • high impact strength • good creep resistance •
low relative volatility under high vacuum.
PVC compounds
Since 2007, Pakistan Cables has been producing flexible PVC compounds for insulation and
sheathing of electric cables, and other flexible PVC compounds for external sale at its
exclusive PVC Compound Plant. Pakistan
Cables uses the most sophisticated
machinery, including automated weighing
and dosing systems for each component of
the various formulations. The plant also has a
polymers laboratory to enable the
development of customer specific formulations.

Crescent cable industry

Crescent Cables is the project of Crown Electric Company established
in 1958. Crescent Cable Industries are the manufacturers of Low and
Medium voltage PVC insulated armored and unarmored Power
Cables, besides XLPE Low and Medium voltage alongside the XLPE HV
Cables. Crescent Cables is approved by all buying agencies in the
country and is used in industrial and domestic installations.

Crescent Cables is the first company in Pakistan to introduce cables

that save energy. Our cables are made with 99.99% pure copper,
imported PVC and guarantee 100% conductivity.
PRODUCT OVER VIEW
Cables used for wiring have copper strands inside them through which
the electricity flows. If the conductivity of the copper is not 100%, the flow faces resistance
causing wastage of electricity. THIS WASTAGE GETS BILLED! The structure of our cables
allows electricity to flow smoothly through the wires without any resistance. Some cable
companies in Pakistan offer cheap cables that are made with low grade material. The result
is low conductivity and high resistance causing current leakages, increased power bills and
risk of damage to health and property. Crescent Cables alleviates all these problems and
offers VALUE RETURN to its customers in short and long term.
Crescent Cables offers a wide range of cables to match your needs. Our product line
includes: general wiring, shielded multi-core flexible cables, power cables, control/flexible
multi-core cables, telephone cables, special cables, automobile cables, and computer cables
(UTP, STP).

USES OF TYPES OF ELECRIC CABLES

Communication Cables
Communications cable is essentially a cable used to transmit information by use of currents
of various frequencies. Communication cable is different from power cables in that power
cables are designed for high voltages and high currents; communication cables are designed
for low voltage and low currents. Communication cables are
typically used for data transmission, electronic circuits,
Ethernet connections and networking.

Coaxial cables
A coaxial cable is used by cable TV service providers to stretch
transmission lines from their branch or control offices to
residential and business subscribers.
Coaxial cables tend to carry signals at a greater distance and are a good choice
for weak signals, due to their layered protection. There are several types of coaxial cables,
which are classified by the inner copper core diameter and number of protective sheaths.

Direct buried cables

The most commonly referred to types of Direct Burial wire are USE (Underground Service
Entrance) – with a thermoset insulation – Tracer Wire and UF, or “Underground Feeder” –
both with thermoplastic insulations. (Note: you might remember some of these terms
from our post on wire abbreviations and wire insulation types).
Direct Burial wire use are running electricity to your home (USE-
2), connecting post lights, locating buried pipes with tracer wire, laying the
sprinklers along golf courses (next time you’re playing a game, remember there are
sometimes 1,000,000’ of wire running underneath you!), and, if you get fancy in the back
yard, hooking up your propane grill to a propane tank in the garage.

Heliax cables
Heliax Cable is part of Allied Wire and Cable’s
extensive stock of Coaxial Cable. This selection of Coaxial
Cables is designed for signal transfers in am/fm radio,
UHF/VHS TV, and other communication systems.
Our HJ, FSJ, and LDF heliax cables are available with a
multitude of jacket materials, depending on your application's fire retardancy
requirements.

Paired cable

Composed of two individually insulated conductors that are

usually used in DC or low-frequency AC applications. Paired
cables allow balanced signal transmission, which results in lower
crosstalk through common mode rejection

Portable cord
 Flexible cable for AC power in portable applications. This covers
portable electric tools and cords used exclusively through
temporary wiring. It also includes portable electric tools and cords
whose source of power may vary from permanent to temporary –
this excludes portable generators – for construction, alteration
and/or repair, including painting and decorating, or that are used in
wet or visibly damp areas.

Ribbon cable
Useful when many wires are required. This type of cable can easily
flex, and It is designed to handle low-level voltages
.
Shielded cable
Used for sensitive electronic circuits or to provide protection in
high-voltage applications.

Single cable
From time to time this name is used for wire.
References:
https://www.elandcables.com/the-cable-lab/faqs/faq-what-is-the-history-of-electrical-
cables
https://en.wikipedia.org/wiki/Electrical_cable
https://www.electronicshub.org/wp-content/uploads/2015/09/US-Color-Code-for-
Electrical-Wiring.jpg (picture link)
https://www.slideshare.net/nisargamin6236/types-of-cables-61156736
http://engineerexperiences.com/electric-power-cables-introduction-and-types.html
http://jyothisanchar.com/history-evolution-of-cables/
https://blogs.siliconindia.com/weyes/Electrical_Cable_Introduction-bid-
14INmxvw79170202.html
https://insightsolutionsglobal.com/manufacturing-process-of-cables-and-wires/

https://www.machinemfg.com/annealing/

https://en.wikipedia.org/wiki/Annealing_(metallurgy)

https://www.sciencedirect.com/topics/engineering/extrusion-process

https://en.wikipedia.org/wiki/Extrusion

https://en.wikipedia.org/wiki/Wire_drawing
https://www.series4.co.uk/wp-content/uploads/2018/01/EC2T.jpg

https://slideplayer.com/slide/10683959/37/images/8/Extrusion+Die+for+Coating+Wire.jpg
www.pionercables.com
www.fast-cables.com
www.gmcables.com
www.pakistancables.com
www.systemswire.com
www.incidentprevention.com
www.sciencedirect.com
www.enwikipedia.com
www.technopedia.com
www.crescentcables.com
www.galaxywire.com
www.britananica.com

Fundamentals of Casting By M P GROOVER 4th EDITION