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PRODUCT@R.P.

G(SILVASSA)
› POWER CABLES(1-4CORES ,10-
1000MM2)

›CONTROL CABLES(1-61 CORES,1-10


MM2)

›SPECIAL DESIGN CABLES(INSTRUMENT


CABLE)
ë   
 

‡ PLANNING AND DESIGN DEPARTMENT


‡ PRODUCTION DEPARTMENT
‡ MAINTANANCE DEPARTMENT
‡ QUALITY CONTROL DEPARTMENT
‡ HR DEPARTMENT
‡ PURCHASE & STORE DEPARTMENT
‡ LOGISTICS & DESPATCH DEPARTMENT
‡ FINANCE &ACCOUNTS

   
  
`  ` 
WIRE DRAWING MACHINE 6
STRANDING MACHINE 4
LAYING UP MACHINE 5
EXTRUDER 7
ARMOURING MACHINE 5
BUNCHER 3
WIRE REWINDING MACHINE 12
CABLE REWINDING MACHINE 3
D. G sets 2(750 KVA,320KVA)
HOT WATER GENERATOR 1(400000 KCAL/HR)
CHILLING PLANT 1(40 TR)
AIR COMPRESSOR PLANT 4
FORK LIFT 2
HYDRA 1


 
ë  

  ëë  ë  


  ë  
› REQUEST FOR QUATATION
› DESIGN AND COSTING
› OFFER SUBMISSION
› QAP & GTP
› OFFER LETTER
› APROVAL FROM H.O (OS)
› ORDER BOOKING
› OC NUMBER
› CABLE CODE
› MONTHLY PLAN(TRACKER SYSTEM)
› CAPACITY OF PLANT BY GROUP
› INSPECTION AND TESTING
› DISPATCH
› PAYMENT COLLECTION
ë  
(1)STANDARD DESIGN AS PER IS

(2) NON STANDARD DESIGN AS PER CUSTOMER


REQUIREMENT

(3)SPECIAL DESIGN CABLE LIKE INSTRUMENT CABLE


‡ IDENTIFY THE CONSTRUCTION OF CABLE

‡ TYPES OF CONDUCTOR INSULATION

‡ ARMOURED/UN ARMOURED

‡ SCREENED(H.T) /UNSCREENED(L.T)
§ §§


 ë 

P 2 0 2 0187

PATRY CODE REGION YEAR INSULATION CUSTOMER


SERIAL NO.

ë ë 


1ST LETTER - PARTY CODE FOR EXAMPLE,P - PRIVATE


1 ST DIGIT - REGION CODE FOR EXAMPLE, 2- MUMBAI ,
4- DELHI ,ETC
2ND DIGIT - YEAR FOR EXAMPLE , 0 ± 2010 , 1-2011
3RD DIGIT - TYPE OF INSULATION. FOR EXAMPLE, 2 ± PVC 7- XLPE
LAST 4 DIGIT - CUSTOMER SERIAL NO. FOR EXAMPLE 0187
GENERAL CODES
 2XWY(P) , A2XWY(T), A2XFY(P), A2XFY(T) , etc.

› A2XFY(T)
A-ALUMINIUM CONDUCTOR
2X ±XLPE INSULATION
F-FLAT STRIP ARMOURING
Y-PVC OUTER SHEATH
(T)- TAPPED INNER SHEATH
(P)- EXTRUDED INNERSHEATH

 



  

ALUMINIUM A

XLPE 2X

PVC INSULATION Y

G.S. ROUND WIRE ARMOUR W

G.S. FLAT WIRE ARMOUR F

AL ROUND ARMOUR Wa

AL FLAT ARMOUR Fa

DOUBLE FLAT STRIP FF


ARMOUR
DOUBLE ROUND WIRE WW

PVC OUTER SHEATH Y

EXTRUDED INNER SHEATH (P)

TAPPED INNER SHEATH (T)


CABLE CODE
a

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

D5 1 5TH AND 6TH DIGIT: VOLTAGE GRADE


D6 8 18- 1.1 KV, 16 ± 1 KV

D7 0 7TH AND 8TH DIGIT:NO. OF CORES


D8 4 03- 3 CORES, 04-4 CORES, 93 - 3.5 CORES

D9 2 9TH AND 10TH DIGIT : AREA


D10 6 26-4MM2,29-6MM2,32-10MM2

D11 4 11TH AND 12TH DIGIT :UP TO 10 MM2, 41- STRANDED & 49- SOLID
D12 1 ABOVE 10 MM2, 49- STRANDED & OTHERS NON STRANDED
 



TYPE:CP

CABLE CODE: a

CORES & CONDUCTOR AREA: 


!

CUSTOMER NAME: MUKUND LTD

PRODUCTION PLAN: 987 MTR

CABLE CONSTRUCTION: "#" 

# 

COPPER (Ø 8.1 mm) , TYPE C, ST-2, G.S.ROUND WIRE .


# ë# 

 #  ë
ë ë 
 

"
# #  $   
DIA. REDUCTION: 0.85
NO OF WIRES:7

#  
ë
% !ë "!




=7X 0.7850X 0.852 X 8.89X0.93
= 32.39KGS/KM
FOR 0.987 KMS = 32.82 X0.987
= 32.39 KGS
FOR 4 CORES
= 32.39X 4 = & ' REQUIRED
ë 

LENGTH REQUIRED: 0.987 X 4C = 3.94 KMS

 

" 
 
NOMINAL THICKNESS: 1 mm

 ë  
AREA = 0.7850 X d2
4 = 0.7850 X d2
Ñ ë % '((
CORE DIAMETER AFTER PVC INSULATION (ë = 2.25 + 2 X 1
Ñ ë % '((
FOR 0.987 KMS = 19.99 X 0.98 7
= 19.737 KG
FOR 4C = 19.737 X 4 = 78.950 KGS
  % '!ë  ë 
= 0.7850 X (4.252- 2.252)
% &((

% !ë "  "

= 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

 
" 
   $ ë% &' 
ë

LAID UP DIAMETER (ëa) = DIAMETER OVER INSULATION X
LAYING FACTOR
= 4.85 X 2.42
ëa % a((
FOR EXTRUDED I/SH POLYESTER TAPE IS USED FOR BINDING
PURPOSE.
   

 
 ) = 0.3 mm
DIAMETER OVER I/SH (ë) = 11.737 + 2X0.3
ë% aa((

    % '!ë  ëa


= 0.7850 X (12.332- 11.372)
= 11.203 mm2

   % !ë "



= 11.20X 1.51
= 16.91 KG/KM

FOR 0.987 KM TOTAL WT. REQUIRED = 16.91 X 0.987


=  & 
 

G.S. ROUND WIRE OF 1.4 MM
DIAMETER AFTER ARMOURING ë' = DIAMETER OVER I/SH + 2 X
THICKNESS
= 46.29 + (2 X 1.4)
ë' %' a((
NO. OF ROUND WIRES REQUIRED
= 3.142 X DIA. ARMOURING X 90ÿ/ ARMOUR SIZE
= 3.142 X 15.130 X 0.90 / (0.7850 X1.42)
= 27.78 7
#   % # !ë "  # !
 # 
= (0.7850 X 1.42) X 7.850 X 27
= 326.10 KGS/KM

 &#   $ ë= 0.987 X 326.10


= 321.86 KGS
INSULATION
  " "  
 
TYPE-A ST-1
TYPE- C ST-2
XLPE ST-2

‡ IN SOME SPECIAL CASES OUTER SHEATH MAY BE


FR,FRLSH,LSZH.
    

)   : ST -2
 
 )  ë
 1.48 mm
DIAMETER OVER O/SH(D6) = DIAMETER AFTER ARMOURING + 2 X
THICKNESS
= 15.130+ 2 X 1.48
ë% &((
AREA OF O/SH = 0.7850 X (D62 ± D52)
= 0.7850X (18.092- 15.1302)
% &((

#     % ) !ë "


= 77.189 X 1.51
= 116.55 KGS/KM

 &= 0.987 X 116.55


= 115.04 KGS
DESIGN OF DRUM

‡ AS PER OUTER DIA OF CABLE, BARREL DIA IS CALCULATED.


‡ BARREL DIA= 12D,D IS OUTER DIA OF CABLE
‡ DRUM SIZE=1000*350*650

‡  

‡  
SUMMARY
 $
 
 )
   

WIRE DRAWING 9 DIE RBD (CU)


1 PROCESS AND 17 DIE RBD COPPER 129.58

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

 #

WIRE DRAWING
COPPER ALUMINUM

STRANDING
SECTOR SHAPE COMPACT CIRCULAR

INSULATION
PVC XLPE

LAID UP
WITH FILLER WITHOUT FILLER

INNER SHEATH
EXTRUDED TAPPED

ARMOURING
ROUND WIRE FLAT STRIPS

OUTER SHEATH
FR FRLS LSZH ST-1 ST-2

TESTING

DISPATCH
ë
ë  
# ë#
‡ ë 
‡ # ë# 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.

‡ ë   
HIGH SPEED STEEL
TUNGSTEN CARBIDE
DIAMOND
  # ë# 
 ALUMINUM(Ø 9.5mm)

 COPPER(Ø 8.0 mm)


# ë#

 

A COOLANT IS A FLUID WHICH PREVENT ITS OVERHEATIN,TRANSFERRING


THE HEAT AND DISSIPATE IT.
" 
 

 ë# 

WIRE DRAWING OIL FORTIFIED WITH HIGH PERFORMANCE WETTING


AGENTS. THIS OIL IS SPECIALLY SUITED FOR DEEP DRAWING OF
ALUMINIUM.

 
  

 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.

›     
 ELONGATION STRENGTH INCREASES

 BETTER FLEXIBILITY

›  
  ë
 STEAM GENERATOR

 TRANSFORMER

 DANCER
" # ë# 
 
   
 ë    
 ë
  ë
*

1. 11 Die RBD (AL wire) 9.5-2.16 22.5

2. 9 Die RBD ( AL wire) 9.5-2.58 25

3. 9 Die RBD (Cu wire) 8-1.4 25 TO 30

4. 7 Die RBD (Fine Al/Cu 3-0.85 22


wire)

5. 17 Die (Fine Cu wire) 2.50-0.3 22.5

6. 21 Die (fine Al /CU wire) 2-0.3 22


LINE DIAGRAM OF 9 DIE RBD

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

ë

› CONDUCTOR IS A SET OF WIRES BUNCHED IN A DIFFERENT
SHAPES. CURRENT RATING DEPENDS ON CONDUCTOR AREA.
AND IT IS DONE BY STRANDING PROCESS.
› " ë
 SECTOR SHAPE
 COMPACT CIRCULAR(16 ± 1000 MM2)
 CIRCULAR(UP TO 10MM2)
›

ë

 CLASS 1(SOLID)
 CLASS 2(STRANDED)
AS PER  MIN NUMBER OF WIRES ARE REQUIERED
 CLASS 5(FLEXIBLE)
AS PER  MAX. WIRE DIA IS MAINTAINED

)   # )# ë  
 ë ë ë

 


1.5 1.38 7/0.53


2.5 1.78 7/0.67
4 2.25 7/0.85
6 2.76 7/1.02
10 3.55 7/1.32
16 7/1.75
25 7/2.16
35 7/2.58
50 7/2.95
70 19/2.16
95 19/2.58
120 19/2.95
150 19/3.26
185 36/2.58
240 36/2.95
300 36/3.26
400 59/2.95
‡  
ë
 

 1.5 MM2 TO 6 MM2

 : 10 MM2 TO 50 MM2

 a70 MM2 TO 150 MM2

 : 185 MM2 TO 1000 MM2


ë 


  
   

1 6+1(TUBLAR) 4-50

2 19 BOBIN 50-150

3 37 BOBIN 70-300

4 61 BOBIN 95-630
 ë &  ë 


1 DIE DIE &


6 BOBIN 12 BOBIN TAKE
BOBBI HOL ROLLER CAPSTON
CAGE CAGE - UP
N DER HOLDER




40HP/30KW, 54.5 AMP, 3-ø SQUIRREL CAGE
INDUCTION MOTOR
TOTAL POWER CONSUMED BY MACHINE:
54.5HP

   `    
› ë 
 

 BASED ON MAIN MOTOR, RPM OF CAGE IS REDUCED THROUGH GEAR BOX.

 IF WE KNOW THE CAGE RPM AND LAY OF CONDUCTOR,

   ë%
 ! "
ë
)

FOR EX, 19- BOBBIN STRANDING MACHINE

MOTOR RPM = 1460

CAGE RPM AT LEVER LOW = 152

LAY OF CONDUCTOR = 166 MM

LINE SPEED = (152 X 166)/1000

=' a

 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


› ë
 
  ë +,

› "   ë  ë 
ë

ë  ë
 

"

 OUTER MOST LAY SHOULD BE IN RIGHT HAND


DIRECTION.
›

  
 FOR CIRCULAR SHAPE
AREA= ʌ/4*D2
WHERE D= DIA. OF CONDUCTOR
 FOR SHAPED CONDUCTOR
AREA= ʌ*r2*/360
WIDTH=2RSIN (/2)
WHERE: R= HEIGHT OF CONDUCTOR AREA

#ë ëë  

   ë
ë

CONDUCTOR
AREA DEGREE SIN(DEGREE/2) DEPTH WIDTH

a   a a a

a         

a   a     a 

a       aa 

a   a a  


EXTRUSION
Plastic extrusion is a high volume manufacturing process in which
raw plastic material (PVC & XLPE) is melted and formed into a
continuous profile.

TYPES:
Pressure extrusion
Sleeve/tube/vaccum extrusion
› " # 
› 

ë
 TYPE A(GENERAL PURPOSE INSULATION FOR 70ÛC)
 TYPE C(HEAT RESISTANCE INSULATION FOR 85ÛC)
› !   (85-90ÛC)
›
 !  
 CURING IS NECESSARY FOR PROPER CROSS LINKING .
 FOR CURING PUPOSE INULATED CONDUCTOR IS HEATED FOR 4
TO 5 HR. AT 90Û C.
 FOR CHEKING OF PROPER CURING OF XLPE HOT SET TEST IS
DONE.
 THICKNESS OF INSULATION IS MAINTAINED AS PER IS.
FLOWCHART

 
Pay-off Cooling trough Tracker  


extruder

Printer

Take-up Caterpillar
' !ë 


 



!0#`%&'%, !() !*) !+#`%&'%, !"#$%&'%m

 !-# .//%'%,

`
^    ^ 

` 
§
 
 

INSULATION INNERSHEATH

   
  
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

  
90mm extruder 1 TO 70
80mm extruder 1 TO 50
150mm extruder 16 AND ABOVE
INSULATION
  " "  
 
0
TYPE-A(700C) ST-1(70 C)
TYPE- C(850C) ST-2(900C)
0 0
XLPE(90 C) ST-2(90 C)

‡ IN SOME SPECIAL CASES OUTER-SHEATH MAY BE


FR,FRLSH,LSZH.
SPECIFICATIONS
SPEED L/D No. OF HEATING TEMP. DRIVE
(rpm) RATIO HEATING CAPACITY REG. (kw)
ZONES (kw) RANGE
(oC)
45mm 10-120 24:1 4 2.4 100-250 15
Extruder
60mm 10-100 24:1 4 2.4 100-250 30
Extruder
80mm 10-100 24:1 4
Extruder
90mm 10-85 24:1 5
Extruder
120mm 8-80 24:1 5
Extruder
150mm 8-72 24:1 6 70 100-275 250
Extruder
CALCULATION
' !ë 

› MOTOR RPM, N = 1500


› Ø OF PULLEY(D1) = 300MM
› Ø OF GB PULLEY(D2) = 450MM
› GEAR RATIO, R = 16.67
› SCREW SPEED = N*D1/D2*R
= 60 RPM
› MATERIAL FLOW RATE: 750 KG/HR (PVC)
CONDUCTOR AREA: 3CX240 MM2
CABLE CONSTRUCTION: A2XFY(P)-FRLSH
› WEIGHT OF INNERSHEATH = AREA OF I/SH * DENSITY
=  )
› LINE SPEED = (MATERIAL FLOW RATE)/(WEIGHT OF
INNERSHEATH)
= 750/284 =  a) 
BEFORE START
 Dismantle the screw & Check if screw & barrel is properly cleaned or not.
 Mount the screw properly.
 Selecting tip & die for desired thickness of a given area of cable.

Tip(ID) = Cable dia. + 4mm


Die(ID) = Tip (OD) + thickness*3

 Insert it in cross-head properly.


 Assemble & fit the cross-head.
 Check the temperature sensors, if they are properly placed or not(In 150mm, it is at
every 515mm of barrel).
 Check the oil circulation of the gearbox.
 Check the cooling water circulation
 Check the tension in the driving belt.
PROCESS
Set the temperature of various zones.
Pre-heating of raw material
Raw material (mixed with catalyst, if required) is fed from a top mounted hopper.
The rotating screw forces the plastic beads forward into the barrel which is heated to
the desired melting temperature of the molten material.
A heating profile is maintained by independent PID controlled heater zones.
It keeps moving forward and reaches decompression zone.
It enters the metering zone.
Enters the cross-head through breaker plate (547 holes of ø=3.2mm)
check for eccentricity and concentricity for achieving desired thickness.
 Pass the cable through extruder by hooking it with a lead wire, which is pulled by the
caterpillar.
PRESSURE ADJUSTMENT OF
CYLINDERS

   1#2&3, 454#,


 
 
 
  
 
 
 
 
 
 
    
‡ SPARK VOLTAGE TEST DURING INSULATION IS DECIDED
AS PER ³I.S.´
    
 
    
   
1 UP TO 1 6
2 1 TO 1.5 10
3 1.5 TO 2 15
4 2 TO 2.5 20
5 ABOVE 2.5 25

‡ EMBOSSING AND PRINTING IS DONE AS PER CUSTOMER


REQUIREMENT.
LAYING-UP
Process of bunching multiple cores with appropriate tooling to form a compact circular
shaped cable.

 Core sequence
 Direction of lay & lay length.
 Width & thickness of tape
 Overlapping ratio of tape
 Use of PVC fillers
LAID UP MACHINE
4  `  4 4

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

5 
    m   
DRUM TWISTER

 

§ 

RDH ! 
 "


Main Motor: 30KW,


415V, 50HZ,
50AMP. 1465RPM
u PAY-OFF SECTOR
Caterpillar: 15kw
CORRECTION
Take-up: 30kw
24 BOBIN MACHINE


 
  
 
 

PAY-OFF
 ! §  ! ! 
§ 

" §    §"

37KW/50HP,
1440RPM,70AMP.,415V
6+1 TUBLAR

1 MAIN GEAR DIE


6 BOBIN CAGE HOLDER
BOBIN MOTOR -BOX

TAK CAPSTON GEAR-


E UP BOX

45KW SLIP-RING
MOTOR, 415V,1500RPM

THE ARMOUR PROTECTS POWER CABLE AGAINST MECHANICAL
DAMAGE OR STRESS & ALSO USED FOR EARTHING PURPOSE.

› "  
 FLAT STRIP ARMOURING(G.S AND ALUMINUM)
 ROUND WIRE ARMOURING(G.S,CU)
 CU TAPES (IN SPECIAL CASE)

› ë  


 4 X 3.4 X 0.8
 6.1 X 5.3 X 1.6

› DIAMETER OF ROUND G.S. WIRE(MM) AS PER


³IS´:1.40,1.60,2.00,2.50,2.8,3.15,6.9
› BEYOND 13MM ROUND WIRES ARE NOT ADVISABLE.
› USE OF CURVATURE IN FLATE STRIP
› DIRECTION OF LAY IN ARMOURING
› NUMBERS OF WIRES/STRIPS CAN BE CALCULATED AS UNDER:
› NO. OF FLAT STRIPS REQUIRED
= 3.142 X DIA. OVER ARMOURING X 90ÿ/ ARMOUR
SIZE
= 3.142 X 47.89 X 0.90 / (4 X 0.8)
= 42.31 42
` §!
#
$ 
   
 "
  

1 42 BOBIN OLD GS ROUND 2-18 1.5-16
WIRE/FLATWIRE
2 42 BOBIN NEW GS ROUND 2-18 1.5-16
WIRE/FLATWIRE

3 32 BOBIN FLATWIRE 2-5 10-150


4 64 BOBIN GS ROUND 1-5 185-1000
WIRE/FLATWIRE

 `


24 42
PAY-OFF BOBIN BOBIN DIE TAPING
CAGE CAGE HOLDER HEAD

ain motor(Slip-ring): TAKE-UP CAPSTON


75kw,1amp,1urpm,
u15V
MAINTANANCE
› TYPES OF MAINTANANCE
 MECHANICAL
 ELECTRICAL

› ROUTINE BREAKDOWN MAINTAINANCE


› CONDITION BASED MAINTAINANCE
› PPM(PLANT PREVENTIVE MAINTAINANCE)

 (MEAN TIME TO REPAIR)


  (MEAN TIME BETWEEN FAILURE)
UTILITIES..
› HOT WATER GENERATER
 OUT PUT : 400000 KCAL/HR
 MAX. TEMP. :1400C
 FUEL :HSD
› WATER CHILLING PLANT
 COMPRESSOR CAPACITY 32 KW
 TOTAL CAPACITY 40 TR
› COMPRESSOR
 IR1(100 CUBIC FEET METER)
 IR2(125 CFM)
 IR3(125CFM)
 ELGI(250 CFM)
› DG SETS
 750 KVA
 320 KVA
› FORK LIFT AND HYDRA
$ "


‡    $   


 
  

 -./-/.- ?6;.::=.?./-  
0.1(23-24535-6-./-/.- (<@.ë.:/5-6./- /.-
2788(9.: 75= 2/ (5//5<:./- /.-
;.5:;9.: 32((24535-6./-.1
 <-.--./-/.-/ .:/53../-.1 '
 <-251<9.: .:/53../-.1'))'

<3=702(4.1 ;/
 6=128357>1.// .2/815:;:/-18(.:-/
:/832-5<:1./5/-2:7.-./- #.5;05:; 15=;.

<:=87-<1 1./5/-2:7.
8AA3.A81:27.
ë  "  
›   
 TESTS MADE BY THE MANUFACTURER TO ALL FINISHED CABLE
LENGTHS TO DEMONSTRATES THE INTEGRITY OF THE CABLE
› "  
 TEST REQUIRED TO BE MADE BEFORE SUPPLY ON A
GENRAL COMERCIAL BASIS ON A TYPE OF CABLES IN
ORDER TO DEMONSTRATE SATISFACTORY PERFORMANCE
CHARACTERISTICS TO MEET THE INTEND APPLICATION
› 


 
 TESTS CARRIED OUT ON SAMPLES TAKEN FROM A LOT FOR
ATHE PURPOSE OF ACEPTANCE OF LOT
›   
 SPECIAL TEST TO BE CARREIED OUT, WHEN REQUIRED BY
AGREEMENT BETWEEN THE PURCHASER AND THE
SUPPLIER
#   
›  
1. TENSILE STRENGTH(85-125 N/MM2)
2. CONDUCTIVITY(37.8*106 S-M-1) DIMENSION MEASUREMENTS
›
 ë
1. TENSILE STRENGTH(210 N/MM2),ELONGATION(32%)
2. CONDUCTIVITY(59.6*106 S-M-1), DIMENSION MEASUREMENTS
› 

ë
1. TENSILE STRENGTH(12.5 N/MM2) & ELONGATION AT
BREAK(125 TO 150%)
2. THERMAL STABILITY
3. HARDNESS
4. SPECIFIC GRAVITY
5. VOLUME RESISTIVITY AT ROOM TEMP. AND ELIVATED TEMP.
› ë#
 MEASUREMENT OF DIMENSIONS
 TENSILE STRENGTH & ELONGATION AT BREAK
 TORSION TEST
 WINDING TEST
 RESISTIVITY TEST
 MASS OF ZINC COATING ON STEEL ARMOUR
 UNIFORMITY OF ZINC COATING ON STEEL
ARMOUR(DIP TEST)

›#ë ë
 VISUAL CHEACKING
 DIMENSION MEASURING
"   ë

 
1. CONDUCTOR RESISTANCE TEST
2. INSULATION RESISTANCE TEST
3. HIGH VOLTAGE TEST
4. SHRINKAGE TEST(XLPE,PVC)
5. HEAT SHOCK TEST(PVC)
6. HOT DEFORMATION TEST(PVC)
7. OXYGEN INDEX TEST(FR,FRLS,LSZH)
8. HOT SET TEST(XLPE)
9. WATER ABSORPTION TEST(XLPE)
11 VOLUME RESITIVITY
12 WATER ABSORPTION TEST(XLPE)
13 FLAMABILITY TEST
14 THERMAL STABILITY
15 MASS OF ZINC COATION ON STEEL ARMOUR(G.S.)
16 UNIFORMITY OF ZINC COATION ON STEEL ARMOUR(G.S.)
17 TENSILE STRENGTH (AL,CU,G.S,PVC& XLPE)
18 TORSION TEST(G.S. WIRE)
19 ANTI RODANE TURMITE TEST
 
›    

 TO FIND OUT CRACKING OF THERMOPLASTIC INSULATION & SHEATH OF


ELECTRICAL CABLE OVERHEATING.

  



 DURING SERVICE OF CABLE IS OVERHEATED WHICH LEAD TO DEGRADATION


OF INSULATION .DUE TO THIS CRACKING OCCUR WHICH TENDS TO FAIL THE
CABLE.

 SAMPLE IS HEATED AT SPECIFIED TEMPERATURE AND DURATION TO


ASCERTAIN WITHSTAND ABILITY AT THAT CONDITION AND CHANGE IS
CHECKED BY VISUAL EXAMINATION.
›   

 TO DETERMINE OF ELONGATION AND PERMANENT SET UNDER LOAD


AT SPECIFIED TEMP. OF INSULATION OF ELECTRIC CABLES

  


 FOR DETERMINATION WEATHER OR NOT THE DEPENDING PROPERTIES


ARE FULLY REALIZED AFTER CROSS LINKING

 IT IS FOR 15 MIN.

 AT 200C.
› ë 

 TO DETERMINE RESISTANCE OF THERMOPLASTIC INSULATION AND


SHEATH OF ELECTRICAL CABLES TO DEFORMATION WHEN
SUBJECTED TO MECHANICAL PRESSURE AT HIGH PRESSURE

 NOT APPLICABLE FOR INSULATION OR SHEATH OF THICKNESS LESS


THAN 0.4MM

  


 THERMO PLASTIC COMPOUND TENDS TO SOFTEN WHEN MAINTAINED


AT HIGH TEMPERATURE OVER A SUFFICIENT PRESSURE

 IN THAT CONDITION THEY ARE SUBJECTED TO MECHANICAL


PRESSURE THAN GET DEFORM AT THE LOCATION OF PRESSURE.
RESULTING IN REDUCTION IN THICKNESS.
›      ë    
 
 

  


 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.



 

 ELONGATION AT BREAK=

GAUGE LENGTH AFTER FRACTURE ± ORIGINAL GAUGE LENGTH

ORIGINAL GAUGE LENGTH


› shrinkage test:
 To determine shrinkage characteristics of thermoplastic
materials
 Significance:
 To determination shrinkage so may not cause any problem
in termination when cables gets heated due to energization
 Terminology: decrease in original length of test specimen
after heat treatment
 No crack should found on cables after test

 ë  
›  "#   

 OPENING RAW MATERIAL STOCK

 CLOSING RAW MATERIAL STOCK

 SUPLLIER PENDING ORDER

 ORDER QUOTATION

 COMPARE THE STATEMENTS

 NEGOTIATION WITH SUPPLIERS

 P.O(PURCHASE ORDER)

 RAW MATERIAL SCHEDULING


 ë 
›   ë  

 SRN (STORE RECEIPT NUMBER)

 FINAL MATERIAL RECIEPT FROM SUPPLIER

 QUANTITY CHEACKING FOR RAW MATERIAL

› 
 

 MATERIAL REJECTION

 RETURN TO SUPPLIER

 REJECTION FROM QUALITY DEPTT.

 PRODUCTION PROCESS DEPTT.


 4
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›
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› %

``
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›   

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 ë 
› INVENTRY
 SOURCING
 INVENTORY MANAGEMENT(STORE)
› TAXES
 DIRECT TAXES
 INDIRECT TAXES
 EXCISE TAX
 SALES TAX
› LOGISTIC
 DESPATCH
 INDIRECT TAXES
 CENTRAL EXCISE
 COMPULSORY ON EVERY FINISHED GOODS
 SALES TAX
›DESPATCH
 MAKING PLAN OF DESPATCH
 ISSUANCE OF CHALAN
 EXCISE INVOICE
 TEST CERTIFICATE
 WARRENTY
 REPLACEMENT POLICY
 AS PER CDD AND QAP PLANNING OF DESPATCH
 PAYMENT TERMS