ELECTRICAL WIRE & CABLE

[EIRI/EDPR/4054] J.C.: 2188XL

INTRODUCTION

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.

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 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.

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 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

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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).

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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.

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 CONTENTS

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:

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(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
(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

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 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

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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 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

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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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 COST ESTIMATION

Plant Capacity 20 MT/Day

Land & Building (4000 [Link].) 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%

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