Detailed Project Report on AAC & ACSR Aluminium Conductors

AAC & ACSR ALUMINIUM CONDUCTORS

[EIRI/EDPR/1368] J.C.: 139

INTRODUCTION

Aluminium Conductors (i) All Aluminium Conducts (AAC) (ii) All Alloy Aluminium Conductors (AAAC), and (iii) Aluminium Conductors Steel Reinforced (ACSR) are used in Transmission and Distribution system to carry the generated electrical energy from generating station to end user. 

The Electrical energy is normally generated at the power stations far away from the urban areas where the consumers are located. There is a large network of conductors between the generating stations and the consumer. 

The network is called the Transmission and Distribution system. The Transmission system is to deliver bulk power from power stations to the load centres and large industrial consumers beyond the economical service range of the regular primary distribution lines where as distribution system is to deliver power from power sector or substations to the various consumers. This transmission and distribution system can employ either overhead system or underground system. Transmission of power, overhead system mainly due to low cost and some other advantages ACSR generally used or transmission line and AAC and AAAC conductors for distribution of power carry out mostly the high voltage transmission. For transmission and distribution of electric power the conductor material used must have the following characteristics: 

i) High conducting i.e. low specific resistance 

ii) High tensile strength in order to withstand mechanical stress 

iii) Low specific gravity in order to give low weight per unit volume 

iv) Low cost in order to be used over long distance 

v) Should not be brittle 

Copper, Aluminium, Steel and Steel cored aluminium, galvanized steel conductors are generally employed for this purpose and preferably stranded in order to increase the flexibility (Solid wires, except of smaller sizes, are difficult to handle and when employed for long spans tend to crystallize at the points of support because of the swinging in winds. Stranded conductors usually have a central wire around which there are successive layers of 6, 12, 18, 24 wires. For 19 layers, the total number of individual wire is 3n (n+1). If the diameter of each strand is torn diameter of the stranded conductors will be (2n+1) d. In the process of manufacture adjacent layers are spiraled in opposite direction, so that the layers are bound together. This method of construction is called as Concentric Lay, out of above mentioned conducting materials, Aluminium is widely used due to its cheapness and many others comparative advantages over other conducting materials. However, owing to the fact that the line or co-efficient of expansion of aluminium is 104 times that of copper, the sag is greater in aluminium wire, therefore, steel cored Aluminium (ACSR) wire is used to compensate this property of Aluminium. The steel conductors used are galvanized in order to prevent rusting and electrolytic corrosion. 

The AAC/AAAC/ACSR conductors for high voltage transmission have first replaced the bore copper conductors where copper is scarce and costly on the other hand EC grade Aluminium is easily available in India and as far as the electric properties are concerned, aluminium is equally good being lighter in weight and for same sage span length of the transmission could be increased in comparison to copper. 

COST ESTIMATION

Plant Capacity            2.93 MT/Day

Land & Building (2000 sq.mt.)    Rs. 1.89 Cr

Plant & Machinery                    Rs. 1.37 Cr

Working Capital for 3 Months    Rs. 1.51 Cr

Total Capital Investment          Rs. 5.04 Cr

Rate of Return                          37%

Break Even Point                      53%

CONTENTS

INTRODUCTION

USES & APPLICATIONS

PROPERTIES OF CONDUCTORS

B.I.S. SPECIFICATIONS

MARKET POSITION

PROJECTED ALUMINIUM USAGE TRENDS IN POWER SECTOR DURING 2012-17

QUALITY CONTROL OF ALUMINIUM CONDUCTORS

MANUFACTURING PROCESS

PROCESS FLOW CHART FOR ACSR CONDUCTOR

PROCESS FLOW SHEET FOR ALL ALUMINIUM ALLOY CONDUCTORS

PLANT LAYOUT

PRINCIPLES OF PLANT LAYOUT

PLANT LOCATION FACTORS

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

MANUFACTURERS/SUPPLIERS/EXPORTERS OF ALUMINIUM CONDUCTOR

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)