Industrial Training at Traco Cables Company Limited: Cochin University College of Engineering KUTTANADU-637215

INDUSTRIAL TRAINING 2017
INDUSTRIAL TRAINING AT TRACO CABLES COMPANY

LIMITED
In partial fulfillment of the requirements for the degree of Bachelor of Technology in
ELECTRICAL & ELECTRONICS ENGINEERING
Of
COCHIN UNIVERSITY OF SCIENCE & TECHNOLOGY
Submitted by
V P THAMJEED
DEPARTMENT OF ELECTRICAL AND ELECTRONICS

ENGINEERING
COCHIN UNIVERSITY COLLEGE OF ENGINEERING
KUTTANADU-610551
COCHIN UNIVERSITY COLLEGE OF ENGINEERING

KUTTANADU- 637215
CUSAT(CUCEK) DEPARTMENT OF EEE

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING
BONAFIDE CERTIFICATE
This is to certify that the industrial training report submitted by “V P THAMJEED” of

semester VI is a bonafide account of the work done by him under our supervision during the
academic year 2016 – 2017.
TRAINING COORDINATOR UNIT HEAD
Submitted on: 26/05/2017

DECLARATION
I sincerely declare that:
1. I am the sole writer of this report
2. The details of training and experience contain in this report describe my involvement as a trainee
in the company TRACO CABLES .
3. All the information contains in this report is certain and correct to my knowledge
V P THAMJEED

ACKNOWLEDGEMENT
I very proudly render my grateful thanks to our Principal Dr. JOB P.A, for providing the
facilities to complete this industrial training.
I are proudly rendering my profound gratitude to the Head of the Department Mrs. SHINY
PAUL, for her encouragement and permitting us to carry out this industrial training.
I extend my sincere thanks and deep sense of gratitude to TRACO CABLE COMPANY and
all the staff who have immensely supported and guided me in completing my industrial
training.
I wish to acknowledge my cordial thanks and deep sense of gratitude to my parents, the
divine power which is ruling this world in the name of truth and various individuals who
helped directly or indirectly to complete my training a successful one.

TABLE OF CONTENT
CHAPTER NO. TITLE

PAGE NO.
ACKNOWLEDGEMENT
LIST OF FIGURES
LIST OF ABBREVIATIONS AND SYMBOLS
1 1.0 INTRODUCTION
1.1 COMPANY FROFILE
1.2 PRODUCTION UNITS
1.3 ORGANISATION STRUCTURE
2 MACHINERIES
3 ACSR
3.0 INTRODUCTION
3.1 TYPES OF ACSR
3.2 MANUFACTURING PROCESS
3.3 FLOW CHART
3.4 APPLICATIONS
3.5 FEATURES

4 ABC
4.0 INTRODUCTION
4.1 MANUFACTURING PROCESSES
4.2 FLOW CHART
4.3 ADVANTAGES
4.4 DISADVANTAGES
5 XLPE
5.0 INTRODUCTION
5.2 FLOW CHART
5.3 APPLICATIONS
6 QUALITY ANALYSIS
6.0 INTRODUCTION
6.1 ROW MATERIALS TEST
6.2 STAGE WISE TEST
6.3 HV TEST
7 FEATURES AVAILABLE IN THE COMPANY
8 CONCLUSION

LIST OF FIGURES
FIGURE TITLE
PAGE
NO. NO.

LIST OF ABBREVIATIONS AND SYMBOLS
 LT - Low Tension
 HT - High Tension
 ACSR - Aluminium conductor steel-reinforced
 XLPE - Cross linked polythene
 ABC - Aerial bunged cable
 KV - Kilo voltage
 & - And
 % - percentage
 Ie, - That is
 Sq mm. - square millimetres

CHAPTER 1
INTRODUCTION
Internships provide real world experience to those looking to explore or gain the relevant knowledge
and skills required to enter into a particular career field. Internships are relatively short term in nature
with the primary focus on getting some on the job training and taking what’s learned in the classroom
and applying it to the real world.
TRACO CABLES COMPANY is a kerala government company and is manufacturing high quality
electrical cables with the progress in the cable technology.
A cable is two or more wire or rope running side and bonded, twisted or braided together to form a
single assembly.in electricity they are used to carry electrical current. Electrical cables are used to
connect tow or more devices, enabling the transfer of electrical signals or power from one device to
the other. Cables are used for wide range of purposes, and each must be tailored for that purpose.
Cables are used extensively in long distance communications, power cables are used for bulk
transmission of alternating and direct current power, especially using high voltage cables.
1.1 COMPANY FROFILE
TRACO CABLE COMPANY LIMITED is a government of kerala undertaking company

incorporated in the year 1960. At first company has two manufacturing divisions, power cable
division and telephone cable division.
The power cable division commissioned in 1965 has facilities for manufacture of P.V.C insulated
armoured and unarmoured heavy duty cables upto 1.1KV with copper/Aluminium conductors, P.V.C
insulated wires and flexibles and bare Aluminium conductors ( A.A.C & A.C.S.R ). All these types of
cables are used for electrical transmission and distribution systems.
In 1974 traco commenced production of paper insulated, lead sheathed, polythene jacketted, copper
telephone cables. After this to enlarge its activities traco has decided to take up manufacturer of
petroleum jelly filled telephone cables.
1.2 PRODUCTION UNITS

HEAD OFFICE :

Reg: Office: 4th Floor, KSHB Office Complex, Panampilly Nagar, P.B. No. 2404, Cochin-682 036,
Kerala, India
FACTORY WORKS AT :
Irimpanam, Via Tripunithura, Ernakulam Dist. -682 309
Chumathra via , Thiruvalla, Pathanamthitta Dist. -689 103
House Wiring Unit Padannakkara,Pinarayi P.O, Thalassery,
Kannur, Pin -670741
1.3 ORGANIZATION STRUCTURE
Organizational Structure
UNIT HEAD
SENIOR SENIOR MANAGE MANAG OFFICER MANAG

MANAG
MANAGE MANAGE R ER ER
ER PURCHASE
R R
CIVIL QUALITY FINANCE
PRODUC
EM & PERSONN ASSURA
TION
PROJECT EL & NCE &
MARKETI
ADMINIS
NG
TRATVE

OFFICER
P&A
CHAPTER 2
MACHINERIES
 Rod break down machine (RBD)

 Tubular stranding machine.
 54 bobbin stranding machine.
 Tripple insulation line (Sioplast)
 Sheathing line (Gelly machine )
 Copper tapping machine.
 Laying up machine.
 Steel strip armouring machine.
 Heavy rewinding machine.

CHAPTER 3
ACSR
3.0 Introduction
Aluminium conductor steel-reinforced cable (ACSR) is a type of high-capacity, high-strength

stranded conductor typically used in overhead power lines. The outer strands are high-purity
aluminium, chosen for its excellent conductivity, low weight and low cost. The center strand is steel
for additional strength to help support the weight of the conductor. Steel is higher strength than
aluminium which allows for increased mechanical tension to be applied on the conductor. Steel also
has lower elastic and inelastic deformation (permanent elongation) due to mechanical loading (e.g.

wind and ice) as well as a lower coefficient of thermal expansion under current loading. These
properties allow ACSR to sag significantly less than all-aluminium conductors.
3.1 TYPES OF ACSR CONDUCTORS
(a) Low tension ACSR cables
 Squirrel
In this type of conductor 6 aluminium strand is surrounded to 1 steel strand both of them
having diameter 2.11mm.
 Weasel
 Rabbit
 Raccoon
(b) High tension ACSR cables
 Moose
 Zebra
 Panther
having diameter 3mm.
 Kundah
In this type of conductor 42 aluminium strand having diameter 3.5mm is surrounded to 7
steel strand having diameter 1.96mm.
 Walf
 Lynx

 Dog
 Coyote
 Drake
 Aluminum wire drawing
Wire and cable used aluminum rod, at room temperature, using wire drawing machine
through one or several drawing die of die hole, the cross section of the decreased and
increased in length and to increase its strength. Drawing is the first process of the wire and
cable companies manufacturing process, the main process parameters are drawing die
technology.
 Twisted
Seven wires are sent in to the LT tubular machine. Wires are stranded and compacted together
to form the conductor.twisted, a plurality of single stranded twisted together, sometimes need
to wrap.
3.3 FLOW CHART

3.4 APPLICATIONS
Used as bare overhead transmission conductor and as primary and secondary distribution conductor
and messenger support. ACSR offers optimal strength for line design. Variable steel core stranding
enables desired strength to be achieved without sacrificing ampacity.
3.5 FEATURES
 high Tensile strength
 better sag properties
 economic design
 best suited for transmission lines with long spans

CHAPTER 4
Aerial bundled cables
4.0 INTRODUCTION
Aerial bundled cables (also aerial bundled conductors or simply ABC) are overhead power lines using
several insulated phase conductors bundled tightly together, usually with a bare neutral conductor.
This contrasts with the traditional practice of using uninsulated conductors separated by air gaps. This
variation of overhead power lines utilizes the same principles as bundled conductors, except that they
are closer together to the point of touching but each conductor is surrounded by an insulating layer
(except for the neutral line).
The main objections to the traditional design are that the multiple conductors are considered
unappealing, and external forces (such as high winds) can cause them to touch and short circuit. The
resultant sparks have been a cause of bushfires in drier climates.

technology.
 Twisted
to wrap.
 Insulation
The conductor is sent to the tripple insulating machine ( 3 extruders ) which melts
polyethylene material, applies it on the wire after which it is sent for cooling. The insulated
wire is passed through a long cooling trough of flowing water to cool and finish the process
of insulation. The triple insulation consists of outer semiconductor, polythene and inner
semiconductor.
After triple insulation the cables are sent for curing inorder to maintain its mechanical
properties/performance and lifespan.
4.2 FLOW CHART


4.3 ADVANTAGES
 Relative immunity to short circuits caused by external forces (wind, fallen branches), unless
they abrade the insulation.
 Can stand in close proximity to trees/buildings and will not generate sparks if touched.
 Little to no tree trimming necessary
 Simpler installation, as crossbars and insulators are not required.
 Ease of erection and stringing, less labor intensive, less construction resources needed.
 More aesthetically appealing.
 Can be installed in a narrower right-of-way.
 At junction poles, insulating bridging wires are needed to connect non-insulated wires at
either side. ABC can dispense with one of these splices.
 Less risk of a neutral-only break from tree or vehicle damage, increasing safety with TNC-s
systems.
 Significantly improved safety for linespersons, particularly when working on live conductors.
 Electricity theft is made harder, and more obvious to detect.
 Less required maintenance and necessary inspections of lines.
 Improved reliability in comparison with both bare conductor overhead systems and
underground systems. Insulated conductors prevent accidental contact and supply can be
maintained temporarily in the event of a suspension system collapse.
4.4 DISADVANTAGES
 Additional cost for the cable itself.

 Insulation degrades due to sun exposure, though the critical insulation between the wires is
somewhat shielded from the sun.
 Shorter spans and more poles due to increased weight.
 Can lead to much longer repair times for installations in hilly areas due to much higher line
weights requiring bigger and more specialized equipment to repair.
 Older installations are known to cause fires in areas where falling large trees or branches
regularly cause breaks in lines and or in insulation leading to short circuits which can then
lead to burning insulation dripping to ground and starting ground fires.
 Failure modes through punctures, electrical tracking, and erosion.

CHAPTER 5
XLPE
5.0 INTRODUCTION
XLPE = Cross-Linked Polyethelene. There are actually two semi-conductive layers on high voltage
cable. One is between the actual conductors and the XLPE. The other semi-con is on outside of the
XLPE insulation underneath the concentric neutral. The semi-con is used to equalize the electrical
stresses over a large area.
technology.
 Twisted
to wrap.
 Insulation
The conductor is sent to the tripple insulating machine ( 3 extruders ) which melts
polyethylene material, applies it on the wire after which it is sent for cooling. The insulated

wire is passed through a long cooling trough of flowing water to cool and finish the process
of insulation. The triple insulation consists of outer semiconductor, polythene and inner
semiconductor.
After triple insulation the cables are sent for curing inorder to maintain its mechanical
properties/performance and lifespan. After curing a copper tapping is done on the cable.
 Laying up machine
The insulated cable are laid up together to form three phase cables and so on. The winding
process is achieved by rotating the bobbins on which they are wound so as to maintain a
uniform twist.
 Sheathing and Armouring

For underground cables a layer of metal armouring ( usually of galvanised steel strip) and
another layer of Polyethelene coating is given.
5.2 FLOW CHART

5.3 APPLICATIONS

These cables are designated for general use including underground burial, where they are not likely to
suffer mechanical damage.

CHAPTER 6
QUALITY ANALYSIS
6.0 Introduction
The different tests are employed to check the quality of the finished cables or raw materials
purchased.
Routine Tests:
These are tests to monitor overall cable quality and function. Tests listed here include high voltage
tests, conductor resistance tests, insulation resistance tests and voltage tests on protective sheath
coverings.
Type Tests:
These tests are used to calibrate and validate cable design type and they include bending tests,
thermal stability tests, impulse voltage tests, head distortion tests, corona level tests and dielectric
thermal resistance tests
Special Tests:
These tests are conducted to ensure major design changes to cables conform to proper performance
tresholds.
After Installation Tests:
These tests are to determine and ensure that cables installed are in optimum operating conditions.
Conductor resistance test on the completed circuit verification tests of cross bonded systems and surge
divertor tests are among the running lists of such critical test requirements.
6.1 ROW MATERIAL TEST
 FOR ALUMINIUM
 Diameter test

This test is carried to check whether the supplied aluminium have the correct
diameter (for aluminium it is 9.5mm)
 Tensile/Breaking load test
In this test a load is applied to a piece of material and its elongation is noted and its
braking point is calculated using suitable equation. From this test we can understand
the maximum load that the material can withstand.
 FOR STEEL
 Diameter test
This test is carried to check whether the supplied steel have the correct diameter.
 Tensile/Breaking load test
In this test a load is applied to a piece of material and its elongation is noted and its
braking point is calculated using suitable equation. From this test we can understand
the maximum load that the material can withstand.
 Wrapping test
Stength of the material is checked by wrapping a piece of material back and forth.
 Torsion test
In this test the steel rod fixed in two ends are rotated back and forth continously in
fixed time.
A good steel rod can withstand upto 13-15 rotations without breaking.
6.2 STAGE WISE TEST
 Resistance test
This test is carried out to check the conductor resistance
Conductors should have a resistance as given below
Squirrel - 8.237 ohm
Weasel - 8.490ohm
Rabbit - 3.265ohm
Raccoon -2.194ohm
 Diameter test
This test is carried out to check the conductor diameter.
Conductors should have a diameter as given below
Squirrel - 2.11+-0.02mm
Weasel - 2.59+-0.03mm
Rabbit - 3.35+-0.03mm
Raccoon -4.09+-0.04mm

 Tensile test
In this test a load is applied to a piece of insulation its elongation is noted and its braking
point is calculated using suitable equation. From this test we can understand the maximum
load that the material can withstand.
Usually done for PVC, XLPE insulations
 Hot set test
In this test a piece of insulation(20mm) is placed in side a thermostatically controlled heating
oven with a weight hanging on it for about 15 minutes under a temperature of 200 degree
Celsius. After 15 minutes elongation of the material is checked if the elongation is above
175% test fails.
 Megger
It is used to find insulation resistance.
6.3 HIGH VOLTAGE TEST
 Heat cycle test

In this test the conductor is heated for 5 hours and then cooled for 2 hours. This process is
repeated for 20 times and will check whether there is any fault.
 Impulse test
A high voltage is applied to the conductor in a short time (ie, an impulse voltage) conductor
should discharge the voltage received with in 1.5 micro second other wise test fails.
Applied Voltage is
74KV for 11KV conductor
120KV for 33KV conductor
 HV test
In this test two ends of the cable is immersed in the transformer oil and a high voltage is
applied on one of the end for about 15 minutes. The applied voltage will be 3.5 times the
phase voltage for which the conductor is designed. Ie, for 11KV cable we apply a voltage
22.22KV ( ie, 3.5×6.35). If there is any fault we can recognise it by a small sound.

CHAPTER 7

FACILITIES AVAILABLE IN THE COMPANY
 SITE
Government of kerala had acquired over 18 acres of land to TRACO at kuttapuzha in
thiruvalla taluk in Pathanamthitta district which has all other locations advantages such as
nearness to trunk road etc..
 WATER
The requirements of water for the operation in the factory will be met from existing well and
pond. In this area there is an abundant supply of ground water for human consumption in this
area.
 POWER
A substation is provided for electricity KSEB has agreed to supply sufficient quantity of
power for the operation in the factory. Also there are two generators available inside the
factory.
 TRANSPORT
The site at kuttapuzha is connected by road and railway. The nearest railway station is only
5Km West of the factory. The distance from the factory site to the main central road is 6Km,
to cochin airport 90Km and to cochin harbour 93Km. Hence there will not be any difficulty
for transport of machinery, raw materials or finished goods from or to any place.

CHAPTER 8
CONCLUSION
For my, internship programme I had taken Traco cables company limited(A kerala government
company), manufacturing high quality Electric Cables and Wires, TRACO has been in the
forefront in meeting the needs of Public Sector Undertakings in India like Railways,
Electricity Boards of various states in the country and others for AAC/ACSR, Power and
Signaling Cables
TRACO CABLES from there I’ve learnt a lot from my work at. the technical aspects of the work I’ve
done are not flawless and could be improved provided enough time.
As someone with no prior experience with this kind of works whatsoever I believe my time spent in
this company was well worth it and contributed to finding an acceptable solution to build a fully
functional cables. Two main things that I’ve learned the importance of our time-management skills
and self-motivation.
Overall my internship at TRACO CABLE has been a success. I was able to gain practical skills and
work in a fantastic environment. I can honestly say that my internship in this company resulted in one
of the best summers of my life. Not only I gain practical skills but also had the opportunity to meet
many fantastic people.

REFERENCE
 Primary data was collected through direct interaction with various officials of the company.
 Secondary data was collected from sources comprising of websites
 www.traco.co
 www.google.com
 www.wikipedia.com

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INDUSTRIAL TRAINING 2017

INDUSTRIAL TRAINING AT TRACO CABLES COMPANY

ELECTRICAL & ELECTRONICS ENGINEERING

COCHIN UNIVERSITY OF SCIENCE & TECHNOLOGY

DEPARTMENT OF ELECTRICAL AND ELECTRONICS

COCHIN UNIVERSITY COLLEGE OF ENGINEERING

COCHIN UNIVERSITY COLLEGE OF ENGINEERING

CUSAT(CUCEK) DEPARTMENT OF EEE

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

This is to certify that the industrial training report submitted by “V P THAMJEED” of

TRAINING COORDINATOR UNIT HEAD

Submitted on: 26/05/2017

CUSAT(CUCEK) DEPARTMENT OF EEE

I sincerely declare that:

1. I am the sole writer of this report

CUSAT(CUCEK) DEPARTMENT OF EEE

CUSAT(CUCEK) DEPARTMENT OF EEE

CHAPTER NO. TITLE

LIST OF ABBREVIATIONS AND SYMBOLS

CUSAT(CUCEK) DEPARTMENT OF EEE

4.1 MANUFACTURING PROCESSES

4.2 FLOW CHART

6.1 ROW MATERIALS TEST

6.2 STAGE WISE TEST

7 FEATURES AVAILABLE IN THE COMPANY

CUSAT(CUCEK) DEPARTMENT OF EEE

CUSAT(CUCEK) DEPARTMENT OF EEE

LIST OF ABBREVIATIONS AND SYMBOLS

 ACSR - Aluminium conductor steel-reinforced

 XLPE - Cross linked polythene

 ABC - Aerial bunged cable

 Sq mm. - square millimetres

CUSAT(CUCEK) DEPARTMENT OF EEE

1.1 COMPANY FROFILE

TRACO CABLE COMPANY LIMITED is a government of kerala undertaking company

1.2 PRODUCTION UNITS

CUSAT(CUCEK) DEPARTMENT OF EEE

Irimpanam, Via Tripunithura, Ernakulam Dist. -682 309

Chumathra via , Thiruvalla, Pathanamthitta Dist. -689 103

House Wiring Unit Padannakkara,Pinarayi P.O, Thalassery,

Kannur, Pin -670741

1.3 ORGANIZATION STRUCTURE

SENIOR SENIOR MANAGE MANAG OFFICER MANAG

CUSAT(CUCEK) DEPARTMENT OF EEE

 Rod break down machine (RBD)

CUSAT(CUCEK) DEPARTMENT OF EEE

Aluminium conductor steel-reinforced cable (ACSR) is a type of high-capacity, high-strength

CUSAT(CUCEK) DEPARTMENT OF EEE

3.1 TYPES OF ACSR CONDUCTORS

(a) Low tension ACSR cables

(b) High tension ACSR cables

CUSAT(CUCEK) DEPARTMENT OF EEE

3.2 MANUFACTURING PROCESS

 Aluminum wire drawing

3.3 FLOW CHART

CUSAT(CUCEK) DEPARTMENT OF EEE

CUSAT(CUCEK) DEPARTMENT OF EEE

Aerial bundled cables

4.1 MANUFACTURING PROCESS

CUSAT(CUCEK) DEPARTMENT OF EEE

 Aluminum wire drawing

4.2 FLOW CHART

CUSAT(CUCEK) DEPARTMENT OF EEE