PPT-NEW

[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



150mm extruder 16 above

MACHINE AREA



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

PPT-NEW

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