Detailed Project Report on copper and aluminium wire & cable unit

COPPER AND ALUMINIUM WIRE & CABLE UNIT

 [CODE NO.4306] 

Wire is used to carry the current from one place to another A wire is a single conductor (material most commonly being copper or aluminium) while cable is two or more insulated wires wrapped in one jacket. Multiple conductors that have no insulation around would be classified as a single conductor.

TYPES OF ELECTRICAL WIRES

There are two main types of wires: solid or stranded. 

A solid wire is a single conductor that is either bare or insulated by a protective colored sheath. It offers low resistance and is perfect for use in higher frequencies. When inside a covering there are many thin strands of wires twisted together, it is called a stranded wire. Stranded wires are used where flexibility is important because which the wire can be used for a longer period. This type of wire have larger cross-sectional area than solid wires for the same current carrying capacity. Stranding is process of twisting together of small wires to form a single larger conductor. Used to provide flexibility, ease of handling and vibration resistance.

Copper Wire

Copper Wire is a single electrical conductor manufactured out of Copper Ore. This widely used conductor can either be insulated or uninsulated. Having a moderate conductivity, it’s used to transfer electricity with low voltage. Electrical wiring in buildings is the largest market for the copper industry worldwide. As per estimation, around half of the copper mines is consumed in manufacturing electrical wire and cable conductors.

COST ESTIMATION

Plant Capacity                                3 MT/Day

Land & Building (6000 sq.mt.)  Rs. 5.04 Cr

Plant & Machinery                              Rs. 2.55 Cr

Working Capital for 2 Months    Rs. 6.52 Cr

Total Capital Investment                  Rs. 14.46 Cr

Rate of Return                                     33%

Break Even Point                                 51%

• INTRODUCTION
• TYPES OF ELECTRICAL WIRES
• THERE ARE TWO MAIN TYPES OF WIRES: SOLID OR STRANDED.
• COPPER WIRE
• PROPERTIES
• PROPERTIES OF COPPER WIRE:
• ALUMINIUM WIRE
• PROPERTIES
• ELECTRICAL CABLE
• PVC COPPER CABLE
• PROPERTY
• APPLICATION
• ADVANTAGES
• ADVANTAGES OF PVC CABLES
• SOME OF THE MAJOR ADVANTAGES OF PVC CABLES
• CONSTRUCTION
• CONDUCTOR
• 1. SOLID/STRANDED
• A. SOLID
• B. STRANDING
• 2. CIRCULAR/ SHAPED
• A. CIRCULAR
• B. SHAPED
• INSULATION
• THE FOLLOWING COLOUR CODE IS USED FOR IDENTIFICATION:
• LAYING UP
• INNERSHEATH
• A. EXTRUDED INNERSHEATH
• B. TAPPED INNERSHEATH
• ARMOURING
• OUTERSHEATH
• USES AND APPLICATION
• B.I.S. SPECIFICATION
• PROCESS FLOW CHART
• MANUFACTURING PROCESS
• (1) DRAWING
• (2) ANNEALING
• (3) STRANDING
• (4) INSULATION
• (5) QUALITY CONTROL
• CABLES ARE MANUFACTURED AND UNDERGO THE FOLLOWING TESTS:
• (A) TYPE TEST
• 1. THE FOLLOWING TESTS ARE TYPE TEST OF ELECTRICAL POWER CABLE.
• PHYSICAL TESTS FOR INSULATION AND SHEATH
• (B) ACCEPTANCE TEST:
• (C) ROUTINE TEST:
• CONDUCTOR RESISTANCE TEST OF ELECTRICAL POWER CABLES
• TEST FOR THICKNESS OF INSULATION OF POWER CABLE
• APPARATUS REQUIRED TESTING FOR THICKNESS OF INSULATION OF POWER CABLE
• PROCEDURE FOR TESTING OF THICKNESS OF INSULATION OF POWER CABLE
• ANNEALING TEST FOR WIRES AND CONDUCTORS
• PROCESS OF ANNEALING TEST FOR WIRES AND CONDUCTORS
• TENSILE TEST OF CONDUCTORS
• APPARATUS REQUIRED FOR TENSILE TEST:
• METHOD OF TENSILE TEST OF CONDUCTORS
• PROCEDURE
• PERSULPHATE TEST OF CONDUCTOR
• WHY COPPER WIRES ARE TINNED?
• METHODS
• METHOD A:
• METHOD B:
• TEST SPECIMEN FOR TINNING TEST (FOR METHOD B)
• WRAPPING TEST FOR CONDUCTORS
• MARKET POSITION
• FINOLEX CABLES
• HAVELLS INDIA
• POLYCAB
• STERLITE TECHNOLOGIES
• KIE INDUSTRIES
• MARKET GROWTH
• OVERVIEW OF WIRES AND CABLE INDUSTRY IN INDIA
• FEW PROFITABLE BUSINESS IDEAS IN WIRE CABLE MANUFACTURINGINDUSTRY
• POWER CABLES
• STITCHING WIRE
• PVC ELECTRIC WIRES & CABLES
• FIBER OPTICAL CABLES
• POWER CABLE
• PVC & XLPE CABLES
• R-F COAXIAL CABLE
• ALUMINIUM WIRE & CABLES
• LT CABLE
• LV CONTROL & POWER CABLES, MV CABLES
• ALUMINIUM WIRE DRAWING WIRE MESH PLANT
• WIRE DRAWING LUBRICANTS
• COPPER WIRE DRAWING (FROM HIGHER SIZE TO VERY THIN SIZE USED IN ELECTRICAL CABLES)
• PLANT LAYOUT
• PRINCIPLES OF PLANT LAYOUT
• MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
• PLANT LOCATION FACTORS
• PRIMARY FACTORS
• 1. RAW-MATERIAL SUPPLY:
• 2. MARKETS:
• 3. POWER AND FUEL SUPPLY:
• 4. WATER SUPPLY:
• 5. CLIMATE:
• SPECIFIC FACTORS
• 6. TRANSPORTATION:
• A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
• 7. WASTE DISPOSAL:
• 8. LABOR:
• 9. REGULATORY LAWS:
• 10. TAXES:
• 11. SITE CHARACTERISTICS:
• 12. COMMUNITY FACTORS:
• 13. VULNERABILITY TO WARTIME ATTACK:
• 14. FLOOD AND FIRE CONTROL:
• EXPLANATION OF TERMS USED IN THE PROJECT REPORT
• 1. DEPRECIATION:
• 2. FIXED ASSETS:
• 3. WORKING CAPITAL:
• 4. BREAK-EVEN POINT:
• 5. OTHER FIXED EXPENSES:
• 6. MARGIN MONEY:
• 7. TOTAL LOAD:
• 8. LAND AREA/MAN POWER RATIO:
• PROJECT IMPLEMENTATION SCHEDULES
• INTRODUCTION
• PROJECT HANDLING
• PROJECT SCHEDULING
• PROJECT CONSTRUCTION SCHEDULE
• TIME SCHEDULE
• SUPPLIERS OF COPPER WIRE AND CABLE
• SUPPLIERS OF ALUMINIUM WIRE AND CABLE
• SUPPLIERS OF RAW MATERIALS
• SUPPLIERS OF COOPER WIRE ROD
• SUPPLIERS OF ALUMINUM WIRE RODS
• SUPPLIERS OF PVC COMPOUND CABLE GRADE
• SUPPLIERS OF PACKAGING MATERIALS
• SUPPLIERS OF PLANT AND EQUIPMENTS
• SUPPLIERS OF WIRE DRAWING MACHINE
• SUPPLIERS OF PVC EXTRUSION PLANT
• SUPPLIERS OF ANNEALING FURNACE
• SUPPLIERS OF WIRE STRANDING MACHINE
• SUPPLIERS OF WIRE STRANDING MACHINE
• SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
• SUPPLIERS OF EOT CRANES
• SUPPLIERS OF DG SETS
• SUPPLIERS OF POWER TRANSFORMERS
• SUPPLIERS OF COOLING TOWER
• SUPPLIERS OF ETP PLANTS
• SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
• SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
• SUPPLIERS OF AIR COMPRESSORS
• SUPPLIERS OF WEIGHING MACHINE (PLATFORM TYPE)
• SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
• SUPPLIERS OF FIRE FIGHTING EQUIPMENTS

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)