Detailed Project Report on electrical wire & cable

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ELECTRICAL WIRE & CABLE

[CODE NO.4054]

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.

PROPERTIES

Properties of Copper Wire:

• Tensile Strength

• Electrical Conductivity

• Strength and Ductility combination

• Creep resistance (it doesn’t change much due to heat)

• Corrosion resistance

• Co-efficient of thermal expansion

• Ease of installation

• Thermal conductivity

• Ability to be soldered

ELECTRICAL CABLE

A cable is defined as the set of conductors, insulators, sheaths and armor protection or shielding, specifically built to carry the current both for energy transportation and for signal transmission.

PVC COPPER CABLE

PVC insulated cables & wires are the ultimate medium for the distribution of electricity. The PVC cables are used for the power distribution in all types of electric wiring, control cables, telephone cables and signaling in Railways. The PVC cable has mostly replaced VIR and CTS cable in domestic as well as industrial wiring due to its long life, moisture resistance, etc

The individual insulated conductors are covered with PVC coatings providing additional electrical and mechanical protection. The cables are suitable for use in sub-station, distribution systems, industrial installation, house wiring and street lighting, etc.

House wire is the simplest of cables and most basic in its construction, manufacture and use. It consists of only two components, viz. conductor (mostly copper) and insulation (mostly PVC) involving three operations – wire drawing, stranding, bunching and extrusion. Before the advent and subsequent extensive use of vinyl compound as insulating materials, vulcanized rubber was most commonly used insulating material for domestic wire as it was for other types of cables. It served the industry and the users very well for several decades until replaced by PVC (Poly Vinyl Chloride).

Property

1. The long-term permissible operation temperature of the conductor shall not be higher than 70℃.

2. Conductor maximum short circuit ((less than 5 second) temperature shall not be higher than 160℃.

3. The cable is not limited by drop in level when being laid, and the environment temperature shall not be lower than 0℃.

4. Perfect chemical stability, resistant against acids, alkalis, grease and organic solvents, and flame retardance.

5. Light weight, perfect bending properties, installed and maintained easily and conveniently.

Application

With the characteristics of stable capability, advanced technology, broad material resources, low price, good flexible and easy to lay and maintain, the PVC Insulated and Sheathed Power Cable are suitable to be laid for distribution line with A.C.50HZ and rated voltage up to 1kV.

COST ESTIMATION

Plant Capacity 20 MT/Day

Land & Building (4000 sq.mt.) Rs. 4.49 Cr

Plant & Machinery Rs. 92 Lac

Working Capital for 2 Months Rs. 49.03 Cr

Total Capital Investment Rs. 54.61 Cr

Rate of Return 35%

Break Even Point 32%

INTRODUCTION

TYPES OF ELECTRICAL WIRES

THERE ARE TWO MAIN TYPES OF WIRES: SOLID OR STRANDED.

COPPER WIRE

PROPERTIES

PROPERTIES OF COPPER WIRE:

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:

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

(6) COILING AND PACKING

MARKET POSITION

MARKET OVERVIEW

EXHIBIT 1: CONSUMER ELECTRICALS SECTOR VALUATION SNAPSHOT

EXHIBIT 2: CABLES AND WIRES INDUSTRY REGISTERED 23% CAGR IN VOLUME TERMS LED BY STRONG DEMAND FROM POWER DISTRIBUTION

EXHIBIT 3: C&W MARKET IN REVENUE TERMS IS EXPECTED TO

DOUBLE OVER FY18-23E

EXHIBIT 4: CABLES AND WIRES DEMAND DRIVERS

EXHIBIT 5: COMPANIES (HAVELLS & FINOLEX) WITH HIGHER SHARE

OF HOUSING WIRES HAVE REGISTERED STRONG MARGINS EXPANSION

EXHIBIT 6: DISTRIBUTION CHANNEL

EXHIBIT 7: MOST OF THE ELECTRICAL PLAYERS HAVE DIVERSIFIED

OVER THE LAST FIVE YEARS

EXHIBIT 8: DEMAND FOR COPPER IS QUITE HIGHER IN EV

EXHIBIT 9: NITIAYOG EV PLAN 2030

EXHIBIT 10: EV INFRASTRUCTURE DEMAND FORECAST

EXHIBIT 11: TRANSMISSION PROGRESS AS ON FEB’19

EXHIBIT 12: FEEDER SEGREGATION PROGRESSING STEADILY

EXHIBIT 13: METRO CONSTRUCTION SENDS ARE EXPECTED

TO ~DOUBLE OVER THE NEXT FIVE YEARS

EXHIBIT 14: RAILWAY ELECTRIFICATION WORK SANCTIONED

EXHIBIT 15: INFRASTRUCTURE SPEND GROWTH TO REMAIN HIGH

EXHIBIT 16: URBAN POPULATION AS A % OF TOTAL POPULATION

EXHIBIT 17: HOUSE SANCTIONED UNDER PMAY (URBAN)

EXHIBIT 18: HOUSE SANCTIONED UNDER PMAY (GRAHMIN)

EXHIBIT 19: SHARE OF HOUSEHOLDS OF TOTAL POWER CONSUMPTION

IS EXPECTED TO INCREASE OVER THE NEXT 5 YEARS

EXHIBIT 20: SHARE OF ORGANIZED PLAYERS WILL IMPROVE TO 74%

BY FY23E

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:

6. TRANSPORTATION:

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 PVC COPPER WIRE

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF COOPER WIRE ROD

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 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)

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