ACKNOWLEGEMENT

It gives me immense pleasure to express my deep sense of gratitude to Mr. Mahesh Sir (Manager, Havells India Ltd.) who gave me the opportunity to undertake training in this organization. I have appreciation and regards for Technical inputs and their constant encouragement, constructive criticism and systematic and sympathetic understanding throughout the course of this training. Without their support it could have never been possible to complete the summer training. I would also like to thank the management and the staff members of the cable manufacturing department as well as the HR department for providing me the relevant information regarding my Project. I thank them all for taking keen interest in my training and guiding me proactively. I also extend my warm thanks to my parents and institute faculty, who always encouraged me to work earnestly during the project work. .

SONU SINGH B.Tech. IV Yr. (ECE)

ABSTRACT
As part of the Bachelor degree for the Science Engineering students, a summer training program for 45 days is required to have a taste of the practical experience for engineers on the job. The training program was during the period at Cables Company- HAVELLS INDIA LTD. ALWAR. This program was assigned to the Engineering Projects Department (EPD) and supervised by the Engineering Projects Manager. The purpose of this report is to show the experience at HAVELLS INDIA LTD. during the summer training period. This report discusses the summer training program at HAVELLS INDIA LTD. during the period. It states briefly the importance of cables and what factors are considered in cable designing process. It mentions some facts about the department that was responsible for the training program. The report describes the process of cable manufacturing at HAVELLS INDIA LTD. Also, it explains the process of designing cables in accordance with international standards and specifications.

II

INDEX 1.
Introduction 1.1 Type of Cables 1.2 General Process Descriptions 1.3 Plant Description 1.4 Introduction to Havells

1
1 2 2 6

2.

Milestone of Havells

3.

Location of Havells plan 3.1 Locations of Manufacturing Plants 3.2 Products Manufacture at Havells

11
11 12

4.

Material Reqd. for Wire

14

5.

Brief Idea of Manufacturing of Cable 5.1 Main Component 5.2 Processes

15
15 16

6.

Flow Chart for Manufacturing Process

17

7.

Various Division at Havells 7.1 Drum Shop 7.2 PVC Composition Plant 7.3 Low/high Voltage Cable Department 7.4 Cable Manufacturing Department

18
18 20 23 25

III

8.

MANUFACTURING PROCESS 8.1 Wire Drawing 8.2 Conductor 8.3 Cabling 8.4 Dielectric Insulation 8.5 Extrusion 8.6 Screening 8.7 Laying Up 8.8 Inner sheath 8.9 Armouring 8.10 Outer Sheath 8.11 Irradiation 8.12 Marking 8.13 Wire stripping 8.14 Final Testing 8.15 Cable Designing 8.16 Packing

26
26 28 29 31 32 34 35 37 38 38 40 41 42 44 45 45

9.

Making Process & Type of Wire Diagram

46 47 47 47 49 50 50 50 50 50 51 53

10. Advantages of PVC & XPLE cable

10.1 Advantages of PVC Cable 10.2 Advantages of XPLE Cable

11. Report Director 12. Safety At Havells

12.1 Primary Hazards of Electricity 12.2 Secondary Hazards of Electricity 12.3 Objective of Safety 12.4 Personnel Protective Equipment 12.5 Safety Equipment to avoid Accidents 13. Bibliography
IV

LIST OF FIGURES
Chapter 1 1.1 Type of Cable 1.2 Flow Chart of Manufacturing Process 1.3 Packed Bundle of wire 1.4 Stranding 1.5 Layout of Package Plant 1.6 Layout of Medium Size plant 1.7 Alwar Plant 1 2 3 4 5 6 7

Chapter 2 2.1 Havells Corporate Office 9

Chapter 3 3.1 MCB 3.2 RCCB 3.3 Capacitor 3.4 CFL 3.5 Havells Fan 10 10 11 12 13

Chapter 4 4.1 Typical Cable 14

Chapter 6 6.1 Flow Chart for XLPE Cable 17

Chapter 7 7.1 Wooden Drum 7.2 PVC Compound 7.3 Low Voltage Power Cable 18 18 19

7.4 Low Voltage Instrument Cable 7.5 High Voltage Cable

21 24

Chapter 8 8.1 Wire Drawing 8.2 Drawing Machine 8.3 Bunching Process 8.4 Cabling 8.5 Cable Insulation Extrusion 8.6 Working of Die 8.7 Extruder 8.8 Laying Up Machine 8.9 Drum Twister 8.10 Irradiation 8.11Laser & Hot Stamp Marking 8.12 Testing of Cable Havells 27 28 29 30 31 33 33 37 38 40 41 45

Chapter 9 9.1 Making Process & Type of Wire Diagram 9.2 Protective Equipment 48 52

VI

LIST OF TABLE

1.1 Type of Machinery 1.2 Production capacity 1.3 Manpower requirement 1.4 power consumption 1.5 Area of land 3.1 Product Manufacture at Havells 11.1 Director Report 2010-11

2 5 5 6 6 15 49

VII