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[email protected](SILVASSA)
POWER CABLES(1-4CORES ,10-1000MM2)
CONTROL CABLES(1-61 CORES,1-10 MM2)
SPECIAL DESIGN CABLES(INSTRUMENT CABLE)
DEPARTMENTS AT RPG CABLES
• PLANNING AND DESIGN DEPARTMENT
• PRODUCTION DEPARTMENT
• MAINTANANCE DEPARTMENT
• QUALITY CONTROL DEPARTMENT
• HR DEPARTMENT
• PURCHASE & STORE DEPARTMENT
• LOGISTICS & DESPATCH DEPARTMENT
• FINANCE &ACCOUNTS
MACHINE LIST AT RPG CABLES, SILVASSA
MACHINE NAME NOS.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
BASIC FUNCTION OF EACH DEPARTMENT
DESIGN
(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)
CABLE CROSS-SECTION
CUSTOMER ORDER : P 2020187
P 2 0 2 0187
PATRY CODE REGION YEAR INSULATION CUSTOMER SERIAL NO.
CODE DESCRIPTION:
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
CABLE CONSTRUCTION :COPPER -------
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 ARMOUR
FF
DOUBLE ROUND WIRE WW
PVC OUTER SHEATH Y
EXTRUDED INNER SHEATH (P)
TAPPED INNER SHEATH
(T)
CABLE CODE
3078 18 04 26 41
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 GRADED6 8 18- 1.1 KV, 16 – 1 KV
D7 0 7TH AND 8TH DIGIT:NO. OF CORESD8 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- SOLIDD12 1 ABOVE 10 MM2, 49- STRANDED & OTHERS NON STRANDED
PLAN
O.C. NO: P2020187
TYPE:CP
CABLE CODE: 3078 18 04 26 41
CORES & CONDUCTOR AREA: 4C X 4MM2
CUSTOMER NAME: MUKUND LTD
PRODUCTION PLAN: 987 MTR
CABLE CONSTRUCTION: YWY(P)- HRPVC
RAW MATERIAL
COPPER (Ø 8.1 mm) , TYPE C, ST-2, G.S.ROUND WIRE .
WIRE DRAWING PROCESS
NUMBER OF WIRES ARE DECIDED ON THE MACHINE CAPACITY AS WELL MIN WIRE REQUIREMENT AS PER IS.DIA. REDUCTION: 0.85NO OF WIRES:7 WEIGHT OF CONDUTCTOR= AREA X DENSITY X
COMPACTIONFACTOR =7X 0.7850X 0.852 X 8.89X0.93 = 32.39KGS/KM
FOR 0.987 KMS = 32.82 X0.987 = 32.39 KGSFOR 4 CORES = 32.39X 4 = 129.58 KGS REQUIRED
STRANDING PROCESSLENGTH REQUIRED: 0.987 X 4C = 3.94 KMS
INSULATION PROCESSTYPE C INSULATION
NOMINAL THICKNESS: 1 mm
CORE DIAMETER:
AREA = 0.7850 X d2
4 = 0.7850 X d2
D1 = 2.25mm
CORE DIAMETER AFTER PVC INSULATION (D2) = 2.25 + 2 X 1 D2 = 4.25mm
FOR 0.987 KMS = 19.99 X 0.98 7
= 19.737 KG
FOR 4C = 19.737 X 4 = 78.950 KGS
AREA OF INSULATION = 0.7850X ( D22 - D1
2 )
= 0.7850 X (4.252- 2.252)
= 14.49 mm2
MASS OF PVC = AREA X DENSITY OF MATERIAL(TYPEC)
= 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
TOTAL PVC (TYPE C) MATERIAL REQUIRED = 78.950 KGS
LAID UP PROCESS
LAID UP DIAMETER (D3) = DIAMETER OVER INSULATION X LAYING FACTOR
= 4.85 X 2.42
D3 = 11.737 mm
FOR EXTRUDED I/SH POLYESTER TAPE IS USED FOR BINDING PURPOSE.
INNER SHEATH PROCESS
THICKNESS OF I/SH = 0.3 mm
DIAMETER OVER I/SH (D4) = 11.737 + 2X0.3
D4= 12.33mm
AREA OF INNER SHEATH = 0.7850X (D42 - D3
2)
= 0.7850 X (12.332- 11.372)
= 11.203 mm2
MASS OF INNERSHEATH = AREA X DENSITY OF PVC (ST-2)
= 11.20X 1.51
= 16.91 KG/KM
FOR 0.987 KM TOTAL WT. REQUIRED = 16.91 X 0.987
= 16.69 KGS
ARMOURING PROCESS
G.S. ROUND WIRE OF 1.4 MM
DIAMETER AFTER ARMOURING (D5) = DIAMETER OVER I/SH + 2 X
THICKNESS
= 46.29 + (2 X 1.4)
D5 = 15.130mm
NO. OF ROUND WIRES REQUIRED
= 3.142 X DIA. ARMOURING X 90/ ARMOUR SIZE
= 3.142 X 15.130 X 0.90 / (0.7850 X1.42)
= 27.78 27
WEIGHT OF ARMOURING = AREA OF WIRE X DENSITY OF G.S.WIRE X NO. OF WIRES
= (0.7850 X 1.42) X 7.850 X 27
= 326.10 KGS/KM
FOR 0.987 KMS WEIGT OF ARMOUR REQUIRED = 0.987 X 326.10
= 321.86 KGS
INSULATION
• IN SOME SPECIAL CASES OUTER SHEATH MAY BE FR,FRLSH,LSZH.
INSULATION TYPE TYPE OF OUTER SHEATH
TYPE-A ST-1
TYPE- C ST-2
XLPE ST-2
OUTER SHEATHING PROCESS
O/SH MATERIAL: ST -2
MINIMUM THICKNESS OF O/SH FOR ARMOURED CABLES: 1.48 mm
DIAMETER OVER O/SH(D6) = DIAMETER AFTER ARMOURING + 2 X THICKNESS
= 15.130+ 2 X 1.48
D6 =18.09 mm
AREA OF O/SH = 0.7850 X (D62 – D5
2)
= 0.7850X (18.092- 15.1302)
= 77.189 mm2
WEIGHT OF OUTER SHEATH= AREA OF O/SH X DENSITY
= 77.189 X 1.51
= 116.55 KGS/KM
FOR 0.987 KMS = 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
• 1)BARREL
• 2)FLANGE
SR NO. PROCESS M/C NAME RMRM REQ ( KGS)
1WIRE DRAWING
PROCESS 9 DIE RBD (CU) AND 17 DIE RBD COPPER 129.58
2STRANDING
PROCESS 6+1 TUBLAR
3INSULATION
PROCESS45 MM
EXTRUDER HRPVC (TYPE-C) 78.95
4 LAID UP PROCESS 6+1 TUBLARPOLYESTER
TAPE
5INNER SHEATH
PROCESS90 MM
EXTRUDER ST-2 16.69
6ARMOURING
PROCESS
42 BOBBIN ARMOURING
MACHINE G.S.ROUND WIRE 272.722
7OUTER SHEATHING
PROCESS90 MM
EXTRUDER ST-2 321.86
SUMMARY
PROCESS FLOW CHART
PRODUCTION DEPARTMENTWIRE DRAWING
• DEFINITION:
• WIRE DRAWING 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.
• DIE MATERIALS:
HIGH SPEED STEEL
TUNGSTEN CARBIDE
DIAMOND
MATERIAL FOR WIRE DRAWING:
ALUMINUM(Ø 9.5mm)
COPPER(Ø 8.0 mm)
WIRE DRAWING
COOLANT:
A COOLANT IS A FLUID WHICH PREVENT ITS
OVERHEATIN,TRANSFERRING THE HEAT AND DISSIPATE IT.
TYPES OF COOLANT:
1. DRAWMET :
WIRE DRAWING OIL FORTIFIED WITH HIGH PERFORMANCE WETTING
AGENTS. THIS OIL IS SPECIALLY SUITED FOR DEEP DRAWING OF
ALUMINIUM.
PERFORMANCE BENEFITS:
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.
BENEFITS OF ANNEALING:
ELONGATION STRENGTH INCREASES
BETTER FLEXIBILITY
ANOTHER MAIN PART OF COPPER RBD:
STEAM GENERATOR
TRANSFORMER
DANCER
TYPES OF WIRE DRAWING MACHINE
SR. NO. NAME OF MACHINE DIAMETERREDUCTION(MM)
AREAREDUCTION IN(%)
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 wire)
3-0.85 22
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
RAW MATE-RIAL
WIRE DRAWING CHAMBER
DAN-
CER-2
DAN-
CER-1
ANNEALING CHAMBER
TAKE-UP
MAIN MOTOR
MAIN MOTOR SPECIFICATION:
160 KW, 270 AMP, 1488 RPM,PF=0.86
CONDUCTOR
CONDUCTOR IS A SET OF WIRES BUNCHED IN A DIFFERENT
SHAPES. CURRENT RATING DEPENDS ON CONDUCTOR AREA.
AND IT IS DONE BY STRANDING PROCESS. TYPES OF STRANDING
SECTOR SHAPE COMPACT CIRCULAR(16 – 1000 MM2) CIRCULAR(UP TO 10MM2)
CLASS OF CONDUCTOR CLASS 1(SOLID) CLASS 2(STRANDED)
AS PER IS MIN NUMBER OF WIRES ARE REQUIERED CLASS 5(FLEXIBLE)
AS PER IS MAX. WIRE DIA IS MAINTAINED
C/S AREA NO.OF WIRES/WIRE DIAMETER
SOLID STRANDNED
(CLASS-1) (CLASS-2)
1.5 1.38 7/0.532.5 1.78 7/0.674 2.25 7/0.856 2.76 7/1.02
10 3.55 7/1.3216 7/1.7525 7/2.1635 7/2.5850 7/2.9570 19/2.1695 19/2.58
120 19/2.95150 19/3.26185 36/2.58240 36/2.95300 36/3.26400 59/2.95
• GROUPS AS PER CONDUCTOR AREA:
GROUP 1: 1.5 MM2 TO 6 MM2
GROUP 2: 10 MM2 TO 50 MM2
GROUP3: 70 MM2 TO 150 MM2
GROUP4: 185 MM2 TO 1000 MM2
STRANDING MACHINE
SR. NO MACHINE NAME AREA(MM2)
1 6+1(TUBLAR) 4-50
2 19 BOBIN 50-150
3 37 BOBIN 70-300
4 61 BOBIN 95-630
LINE DIAGRAM OF 19 BOBIN STRANDING MACHINE
1 BOBBI
N
6 BOBIN CAGE
DIE HOLDER
12 BOBIN CAGE
DIE & ROLLER HOLDER
CAPSTONTAKE- UP
MAIN MOTOR SPECIFICATION:40HP/30KW, 54.5 AMP, 3-ø SQUIRREL CAGE
INDUCTION MOTORTOTAL POWER CONSUMED BY MACHINE:
54.5HP
HOW TO FIND MACHINE CAPACITY?
STRANDING MACHINE:
BASED ON MAIN MOTOR, RPM OF CAGE IS REDUCED THROUGH GEAR BOX.
IF WE KNOW THE CAGE RPM AND LAY OF CONDUCTOR,
LINE SPEED = (CAGE RPM X LAY OF CONDUCTOR)/1000
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
=25.23 MPM
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
D.C RESISTANCE MUST BE MAINTAINED AS PER “IS”
LAY LENGTH DEPENDS UPON THE CONDUCTOR
DIAMETER AND MACHINE CAPACITY.
OUTER MOST LAY SHOULD BE IN RIGHT HAND
DIRECTION.
CALCULATION OF AREA
FOR CIRCULAR SHAPE
AREA= π/4*D2
WHERE D= DIA. OF CONDUCTOR FOR SHAPED CONDUCTOR
AREA= π*r2*Ѳ/360
WIDTH=2RSIN (Ѳ/2)
WHERE: R= HEIGHT OF CONDUCTOR AREA
WIDTH AND DEPTH CALCULATION FOR SHAPED CONDUCTORCONDUCTOR
AREA DEGREE SIN(DEGREE/2) DEPTH WIDTH
300 60 0.5 23.94261 23.94260653
300 90 0.707106781 19.54906 27.64654066
300 100 0.766044443 18.54586 28.41391101
300 120 0.866025404 16.92998 29.32358456
300 180 1 13.82327 27.64654066
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
TYPES OF RAW MATERIAL
PVC COMPOUND
TYPE A(GENERAL PURPOSE INSULATION FOR 70˚C)
TYPE C(HEAT RESISTANCE INSULATION FOR 85˚C)
XLPE(SIOPLAS)(85-90˚C)
CURING OF XLPE:
CURING IS NECESSARY FOR PROPER CROSS LINKING .
FOR CURING PUPOSE INULATED CONDUCTOR IS HEATED FOR 4
TO 5 HR. AT 90˚ C.
FOR CHEKING OF PROPER CURING OF XLPE HOT SET TEST IS
DONE.
THICKNESS OF INSULATION IS MAINTAINED AS PER IS.
FLOWCHART
Pay-off
extruder
Cooling trough Tracker
Printer
Take-up Caterpillar
Spark voltage tester
Clamp
TipClamp
Heater
Blower
Gearbox
Material flow
Z-1(feeding zone)Z-4,Z-3,Z-2(Melting zone)
Z-5(Decompression zone)
Z-6(Metering zone)
150MM EXTRUDER
MOTOR
PULLEYPULLEY
REDUCTION GEAR,
¡=16.67
Ø=300MMØ=230MM
INSULATION INNERSHEATH
OUTERSHEATH
MACHINE AREA
45mm extruder -I 1TO 4
45mm extruder-II 1 TO 6
60mm extruder 2.5 TO 70
120mm extruder 35 TO 630
MACHINE AREA
90mm extruder 1 TO 70
80mm extruder 1 TO 50
150mm extruder 16 above
MACHINE AREA
90mm extruder 1 TO 70
80mm extruder 1 TO 50
150mm extruder 16 AND ABOVE
INSULATION
• IN SOME SPECIAL CASES OUTER-SHEATH MAY BE FR,FRLSH,LSZH.
INSULATION TYPE TYPE OF OUTER SHEATH
TYPE-A(700C) ST-1(700C)
TYPE- C(850C) ST-2(900C)
XLPE(900C) ST-2(900C)
SPECIFICATIONSSPEED
(rpm)
L/D RATIO
No. OF HEATING
ZONES
HEATING CAPACITY
(kw)
TEMP. REG.
RANGE (oC)
DRIVE (kw)
45mm Extruder
10-120 24:1 4 2.4 100-250 15
60mm Extruder
10-100 24:1 4 2.4 100-250 30
80mm Extruder
10-100 24:1 4
90mm Extruder
10-85 24:1 5
120mm Extruder
8-80 24:1 5
150mm Extruder
8-72 24:1 6 70 100-275 250
CALCULATION150MM EXTRUDER :
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
= 284 KG/KM LINE SPEED = (MATERIAL FLOW RATE)/(WEIGHT OF
INNERSHEATH)
= 750/284 = 2.63 KM/HR
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 materialRaw 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
WEIGHT OF CABLE (kg/m) PRESSURE (bar)
2.5 1.4
5 1.6
7.5 1.75
10 1.85
12.5 2
15 2.15
17.5 2.25
20 2.4
22.5 2.60
25 2.75
SPARK VOLTAGE TESTER
• SPARK VOLTAGE TEST DURING INSULATION IS DECIDED AS PER “I.S.”
• EMBOSSING AND PRINTING IS DONE AS PER CUSTOMER REQUIREMENT.
SR. NO. INSULATION THICKNESS(IN MM)
SPARK VOLTAGE(RMS VALUE IN KV)
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
LAYING-UP
Process of bunching multiple cores with appropriate tooling to form a compact circular shaped cable.
Core sequenceDirection of lay & lay length. Width & thickness of tapeOverlapping ratio of tapeUse of PVC fillers
LAID UP MACHINE
SR.NO. MACINE AREA CORE
1 4+1 6-50 2 TO 5
2 3+1 70-630 2 TO 4
3 DRUM TWISTER
16-185 2 TO 4
4 24 BOBIN 1.5-2.5 2 TO 61
5 6+1( Tubular) 1-7 2TO 7
DRUM TWISTER
RDH TPHCATERPIL
LARBINDER TAKE-UP
4 PAY-OFF SECTOR CORRECTION
Main Motor: 30KW, 415V, 50HZ, 50AMP. 1465RPMCaterpillar: 15kwTake-up: 30kw
ROTATING PART
24 BOBIN MACHINE
P
TRACKER
TAPING HEAD
DIE HOLDER
6 BOBIN CAGE
18 BOBIN CAGEPAY-OFF
DIE HOLDER
CAPSTONTAKE-UP
37KW/50HP, 1440RPM,70AMP.,415V
6+1 TUBLAR
1 BOBIN
CAPSTONTAKE UP
45KW SLIP-RING MOTOR, 415V,1500RPM
MAIN MOTOR
GEAR-BOX
GEAR-BOX
6 BOBIN CAGEDIE
HOLDER
ARMOURINGTHE ARMOUR PROTECTS POWER CABLE AGAINST MECHANICAL
DAMAGE OR STRESS & ALSO USED FOR EARTHING PURPOSE.
TYPES OF ARMOURING: FLAT STRIP ARMOURING(G.S AND ALUMINUM) ROUND WIRE ARMOURING(G.S,CU) CU TAPES (IN SPECIAL CASE)
DIMENSION OF FLAT STRIP: 4 X 3.4 X 0.8 6.1 X 5.3 X 1.6
DIAMETER OF ROUND G.S. WIRE(MM) AS PER “IS”: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 90/ ARMOUR SIZE
= 3.142 X 47.89 X 0.90 / (4 X 0.8)
= 42.31 42
MACHINES@RPG,SILVASSA
SERIAL NO.
MACHINE TYPE CORE AREA
1 42 BOBIN OLD GS ROUND WIRE/FLATWIRE
2-18 1.5-16
2 42 BOBIN NEW GS ROUND WIRE/FLATWIRE
2-18 1.5-16
3 32 BOBIN FLATWIRE 2-5 10-150
4 64 BOBIN GS ROUND WIRE/FLATWIRE
1-5 185-1000
64 BOBIN ARMOURING
PAY-OFF24
BOBIN CAGE
42 BOBIN CAGE
DIE HOLDER
CAPSTON
TAPING HEAD
TAKE-UPMain motor(Slip-ring): 75kw,136amp,1400rpm,415V
MAINTANANCE
TYPES OF MAINTANANCE MECHANICAL ELECTRICAL
ROUTINE BREAKDOWN MAINTAINANCE CONDITION BASED MAINTAINANCE PPM(PLANT PREVENTIVE MAINTAINANCE)
MTTR(MEAN TIME TO REPAIR) MTBF(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
QUALITY CONTROL
• VARIOUS TESTING EQUIPMENTS AVAILABLE AT RPG CABLES SILVASSA
HV test setThermal Stability test setVacuum OvenAgeing OvenHot Set test setsHot air ovenCold chamberHydraulic pressInsulation resistance test
Oxygen Index Test SETSmoke Density Test setAcid Gas Emission Test setFlammability TesterTensile Tester 0 - 25 KNTensile Tester 50/100/250 KgsMeasuring InstrumentsWeighing BridgeConductor resistanceMuffle furnace
DIFFERENT TYPE OF TESTS ROUTINE TEST
TESTS MADE BY THE MANUFACTURER TO ALL FINISHED CABLE LENGTHS TO DEMONSTRATES THE INTEGRITY OF THE CABLE
TYPE TEST 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
ACCEPTANCE TEST TESTS CARRIED OUT ON SAMPLES TAKEN FROM A LOT
FOR ATHE PURPOSE OF ACEPTANCE OF LOT OPTIONAL TEST
SPECIAL TEST TO BE CARREIED OUT, WHEN REQUIRED BY AGREEMENT BETWEEN THE PURCHASER AND THE SUPPLIER
RAW MATERIAL TESTS
ALUMINIUM
1. TENSILE STRENGTH(85-125 N/MM2)
2. CONDUCTIVITY(37.8*106 S-M-1) DIMENSION MEASUREMENTS COPPER ROD
1. TENSILE STRENGTH(210 N/MM2),ELONGATION(32%)
2. CONDUCTIVITY(59.6*106 S-M-1), DIMENSION MEASUREMENTS PVC COMPOUND
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.
ARMOURED WIRE MEASUREMENT OF DIMENSIONS TENSILE STRENGTH & ELONGATION AT BREAKTORSION TESTWINDING TESTRESISTIVITY TEST MASS OF ZINC COATING ON STEEL ARMOURUNIFORMITY OF ZINC COATING ON STEEL
ARMOUR(DIP TEST)
WOODEN DRUMS
VISUAL CHEACKINGDIMENSION MEASURING
TYPES OF TESTS OF FINISHED CABLES
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
TESTS
HEAT SHOKE TEST:
TO FIND OUT CRACKING OF THERMOPLASTIC INSULATION & SHEATH OF
ELECTRICAL CABLE OVERHEATING.
SIGNIFICANCE:
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.
HOT SET TEST:
TO DETERMINE OF ELONGATION AND PERMANENT SET UNDER LOAD
AT SPECIFIED TEMP. OF INSULATION OF ELECTRIC CABLES
SIGNIFICANT:
FOR DETERMINATION WEATHER OR NOT THE DEPENDING
PROPERTIES ARE FULLY REALIZED AFTER CROSS LINKING
IT IS FOR 15 MIN.
AT 200C.
HOT DEFORMATION :
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
SIGNIFICANCE
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.
TENSILE STRENGTH AND ELONGATION AT BREACK OF ARMOUING
MATERIAL
SIGNIFICANT:
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.
CALCULATION :
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
PURCHASE DEPARTMENT
MONTHLY RAW MATERIAL PLANING
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
STORE DEPT STORE INBOUND MATERIAL:
SRN (STORE RECEIPT NUMBER)
FINAL MATERIAL RECIEPT FROM SUPPLIER
QUANTITY CHEACKING FOR RAW MATERIAL
MISCELLANEOUS
MATERIAL REJECTION
RETURN TO SUPPLIER
REJECTION FROM QUALITY DEPTT.
PRODUCTION PROCESS DEPTT.
TYPES OF RAW MATERIALSPVC RAW MATERIAL
TYPE ATYPE CST1ST2FR, FRLS , LSZH
SIOPLAS(XLPE)GS ROUND WIRE
1.4 MM1.6MM 2.0MM2.5MM2.8MM3.5MMGS FLAT STRIP
4*3.4*0.86.1*5.3*1.4
COMMERCIAL DEPTT.
INVENTRY SOURCING INVENTORY MANAGEMENT(STORE)
TAXES DIRECT TAXES INDIRECT TAXES
EXCISE TAXSALES 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