Induction Training Program

23RD SEPTEMBER 2010- 24TH OCTOBER 2010

KEC INTERNATIONAL LTD.(RPG CABLES)
SILVASSA
 Overview
Company profile
Line of action
Basic cable construction
Planning department
Design department
Production department
Testing department
Engineering services
 KEC International ltd.
Kamani Engg. Corp. established for manufacture, enamelling and trading
for Hollowware in 1945.
Taken over by RPG group in 1982.
Name changed to KEC International Ltd. in 1984.
KEC International Ltd. took over RPG cables in 2010.
KEC today has excellent Project Management capabilities in five major
business areas:
Power Transmission
Power Distribution & Design Services
Telecommunications Infrastructure
Railway Infrastructure
Cables Manufacturing
Water harvesting
 RPG Cables Profile
• Started in 1959 at Thane, Mumbai

• Pioneer in Cable industry, headquartered in Mumbai, India.

• Outcome of the merger of Asian Cables Ltd.(Thane), RPG Telecom Ltd.

(Mysore) & Upcom Cables Ltd (Rae Bareli) in 1995.

• Oldest company of the RPG Group.

• Part of the Transmission Sector of the RPG Group since 2008.

• Brand name 'Asian' is 50 years old.

• Approx 40000 shareholders.

• KEC International Ltd. took over RPG cables in 2010.

Product Range
 Products at silvassa
• Power cables(1-4 cores,
10-1000mm2)

• Control cables(1-61 cores,

1-10 mm2)

• Special design
cables(instrument cable)
 Silvassa Plant
Departments:
 Line Of Action
Customer

MARKETING

COSTING

PLANNING

ACCOUNTS DESIGN
PURCHASE

PRODUCTION

Q/C TESTING

DESPATCH

CUSTOMER
 BASIC CONSTRUCTION
Sr.no. Components Functions Desired properties

1 Conductor To carry normal rated current, High electrical

overload & short circuit current. conductivity, good
mechanical
properties &
flexibility
2 Insulation To withstand normal system Good dielectric
voltage, sustained over voltage & properties & heat
transient over voltage. dissipation
characteristics.

3 Screen To make uniform electric field Semi-conducting

distribution & carry current under properties for non-
fault condition. metallic screen &
high electrical
conductivity for
metallic screen.
 Cont..
4 Filler To provide circular shape Non- hygroscopic.
to cable. Compatibility with insulation
& sheathing material.

5 Inner sheath To bind cores of cable Good mechanical & thermal

together & provide a properties.
bedding for armor.
6 armor To provide protection High mechanical strength,
against external reasonable electrical
mechanical forces. conductivity & corrosion
To carry current during resistant.
fault conditions.
7 Outer sheath To provide external Good mechanical & thermal
covering & protection to properties. Flexibility.
the cable. Fire retardant, and low
smoke, anti-termite, uv
resistance
Planning Department

GUIDED BY:
MR.PRADEEP
Department Interface
 Functions
Interface between plant and marketing
Freezing of order after technical and commercial
clearance
Decide delivery date
 prepare production schedule for a month
Provide raw material details to the purchase
department
keeps track of every job on the tracker
Accordingly arrange the customer inspection date
Dispatch
 Cable Type
SR. CONSTITUENT CODE LETTER
NO.
1 Aluminum conductor A
2 XLPE insulation 2X
3 Steel round wire armor W
4 Non magnetic round wire armor Wa
5 Steel strip armor F
6 Non magnetic strip armor Fa
7 Double steel round wire armor WW
8 Double steel strip armor FF
9 PVC outer sheath Y
10 Extruded inner sheath (P)
11 Taped inner sheath (T)
 Cable Code
2550-18-03-80-00
 Order confirmation number
P 3070444
GROUPS AS PER CONDUCTOR AREA:

Group 1: 1.5 mm2 to 6 mm2

Group 2: 10 mm2 to 50 mm2

Group3: 70 mm2 to 150 mm2

Group4: 185 mm2 to 1000 mm2

Group h: house wiring

 Tracker
 Tracker is one of best example of MICROSOFT EXCEL as
a very effective tool in manufacturing industry.
 Tracker keeps up to date records of every raw material to
finished product.
 We manufacture 600+orders of cable in a month.
 We manufacture 400+ types of cables.
 So, it is a very tedious task to keep track of each and every
order.
 Everyone can keep a track of every work order with the
help of tracker.
 We can predict our plan of action if we are running late.
Design Department

GUIDED BY:
MR. S. KADAM
Department Interface
 Functions
• Shaping the requirements of the customer by applying
standards and engineering experience.
• Receiving enquiries of floated tender from customers
through marketing department.
• Marketing department receives queries from regional
offices.
• Prepares GTP, BOM & Offer as per requirement and
forwarded to marketing department.
• Confirms the Quality assurance plan.
• Prepares manufacturing specification and hand over to
production department.
 Standards
There are some standards which are generally followed by the design
department on the basis of voltage grade of cable or
customers requirement.
 Design of cables:
Conductor:
The choice of conductor material, size and design must
take following into consideration.
Ampacity
Voltage stress at the conductor
 Voltage regulation
 Conductor losses
 Bending radius and flexibility
 Overall economics
 Material considerations
 Mechanical properties
 Material consideration
• Resistivity of metal at 20 0C

Metal Ohm-mm2 /m x 10-8

Silver 1.629
Copper annealed 1.724
Copper hard drawn 1.777
Copper tinned 1.741 – 1.814
Aluminum, soft, 61.2% cond. 2.803
Aluminum, ½ hard to full hard 2.828
Sodium 4.3
Nickel 7.8
Large size of solid conductors becomes to rigid to form,
install and terminate.
In large size of solid conductor AC resistance is increased
due to skin effect and proximity.
Stranding becomes solution to these problems.
Types of stranding :
 Concentric stranding
 Compressed stranding
 Compact stranding
 Bunch stranding
 Rope stranding
 Sector conductor
 Segmental conductor
 Annular conductor
 Unilay conductor
Insulation
Properties required
 Low dielectric constant
 Low power factor
 High dielectric strength
 Moisture resistance
 High resistance to chemical and solvents

Materials

Polymer type Properties

LDPE Low dielectric loss
Moisture sensitive
XLPE Slightly higher losses vs. PE
Age better then PE
PVC Must contain plasticizer for
flexibility
Higher losses
 Comparison
Properties XLPE PE PVC

Normal Rated temp 90 70 70

Short ckt. Temp` 250 140 160

Tensile strength 2.35 1.4 1.25 to 2.5

Power factor x 10-4 4 4 1000

Volume resistivity at >10^15 >10^15 >10^13

20 0C
Dielectric strength 50 50 20 to 35
KV/mm
Armoring
Properties required
 Reasonable conductivity
 Mechanical strength
 Flexible

Materials
G.S. flat wire
G.S. round wire
Aluminum
Copper
• OUTER SHEATH
•Properties required
• Good mechanical & thermal properties.
• Flexibility
• Fire retardant
• low smoke
• anti-termite
• uv resistance
INSULATION TYPE TYPE OF OUTER
SHEATH
0
TYPE-A(700C) ST-1(70 C)
TYPE- C(850C) ST-2(900C)
XLPE(900C) ST-2(900C)
 Design calculation

 O.C. NO : P3070444

 TYPE : AX

 CABLE CODE : 2550 18 93 52 49

 CORES & CONDUCTOR AREA: 3.5C X 70MM2

 CUSTOMER NAME: ORISSA MANGANESE

 PRODUCTION PLAN: 4500 MTR

 CABLE CONSTRUCTION: A2XFY(P)

 WIRE DRAWING PROCESS
 NUMBER OF WIRES ARE DECIDED BASED ON MIN WIRE
REQUIREMENT AS PER IS-8130/1984.
 Main conductor
 Wire diameter : 2.16 mm
 No. of wires : 19
 Weight Of Conductor = Area X Density X Compaction factor
= 19 X 0.7850 X 2.162 X 2.703 X 0.93
= 175 KG/KM
 FOR 4.5 KMS = 175 X 4.5
= 787.5 KG
 FOR 3 CORES = 787.5 X 3
= 2362.5 KG
 Neutral conductor
 Wire diameter : 2.52 mm
 No. of wires : 7
 Weight of neutral conductor = 394.94 KG
 STRANDING PROCESS
 Main conductor :
 Length required: 4.5 x 3c = 13.5 km
 Sector angle = 1000
 Depth of conductor = area  360
  deg

= 8.95 mm


 Width of conductor = 2  sin  depth
2

= 13.71mm
 Neutral conductor
 Length required: 4.5 x 1c = 4.5 km
 Sector angle = 600
 Depth = 8.174 mm
 Width = 8.174 mm
 INSULATION PROCESS
 XLPE insulation :
 Nominal thickness: 1.1 mm (IS : 7098/I)
 Main Core diameter:
 Area = 0.7850 X d2
D1 = 9.28 mm
 Core diameter after XLPE insulation (dc1) = 9.28 + 2 x1.1

dc1 = 11.48mm
 Total weight of main conductor = area X density X length X no. of cores

= 445.5kg

 Neutral core diameter (d2)= 6.67 mm

 Core diameter over XLPE insulation (dc2)= 6.47 mm
 Weight of XLPE for neutral conductor = 88.61 kg

 Total weight of XLPE = 445.5 + 88.61

=534.11 kg
  Laid up diameter (DT) = 2.48 x (3 x dc1 + dc2) / 4

= 25.96 mm

INNER SHEATH PROCESS

• Thickness of I/SH = 0.4 mm (AS PER IS 7098/PART I)
• Diameter over inner sheath (D3) = 25.97+2 x 0.4
= 26.76
mm

• Area of inner sheath = 0.7850 x (d32 - dt2)

= 33.13 mm2

• Weight of inner sheath = area x density of PVC (st-2) length

= 33.13 x 1.51 x 4.5
= 223.6 kg
 ARMORING PROCESS

 G.S. flat strip of 1.4 mm

 Diameter after armoring (d4) = diameter over I/SH + 2 x thickness

= 26.76 + (2 x 0.8)
= 28.37mm

 No. Of flat wires required = 3.142 x Dia.Under armoring x 90 /armor size

=19

 Weight of armoring = area of wire x density of G.S.Wire x no. of wires x length

= (4 x 0.8) x 7.850 x 19 x 4.5

= 2147.76 kg
 OUTER SHEATH
 Minimum thickness of the outer sheath = 1.56 mm

 Diameter over outer sheath (d5) = d4 + 2x thickness

=31.48 mm

 Area of outer sheath = 146.63 mm2

 Total weight of outer sheath = area of outer sheath x density x length

= 996.38 kg
Production Department

GUIDED BY:
MR. UMESH CHANDRA
MR. L.K.MISHRA
MR. YADAV
Department Interface
 Functions
Prepares master production schedule for a month
Raw material requisition
Prepare job cards from manufacturing specification
Prepare job process sheet
Update daily production shift wise in tracker
Coordination with maintenance department
Coordination of man, machine, material.
 Basic Process Flowchart

Raw Wire
Materials
Annealing Redrawing Stranding
drawing

1 core PVC Insulation

Inner
Sheath
Multi curin
Laying Up XLPE
core g

Outer Final
armoring inspection Dispatch
Sheath Testing
 Machine layout
Sr Name Sr Name
. .
1 11-die Al 13 Winding m/c
2 9-die Cu 14 Winding m/c
3 9-die Al 15 32 bobbin
4 17-die fine Cu 16 Annealing furnace
5 7-die fine Al 17 Cable rewinding
6 19 bobbin 18 Cable rewinding
7 Winding m/c 19 120 mm extruder
8 Winding m/c 20 61 bobbin
9 Winding m/c 21 Drum twister
10 42 bobbin new 22 Winding m/c
11 37 bobbin 23 21 die Al
12 6+1 laying up 24 Office
Plant 1 25 workshop
 Machine layout
Sr. Name Sr. name
1 Buncher-1 13 150 mm extruder
2 Buncher-2 14 80 mm extruder
3 Buncher-3 15 64 bobbin
4 Winding m\c 16 Cable maintenance
5 45 mm extruder 17 42 bobbin –old
6 45 mm extruder 18 4+1 laying up
7 90 mm extruder 19 3+1 laying up
8 24 bobbin 20 Testing
9 Winding m/c 21 Testing
10 6+1 laying up 22 Winding m/c
11 Winding m/c 23 Winding m/c
12 60 mm extruder 24 Winding m/c
25 office
Plant 2
 Wire Drawing
 In wire drawing, the copper or aluminum rod is drawn
through a series of successively smaller dies to reduce the
rod to a wire of the desired diameter.
 Here the entire process is carried out in weight and not in
meters.
 Lubrication:
-For Copper wire- Soap foam /Draw Met 44
-For Aluminum wire- Draw Met 15
 Drawn wire is further send for Annealing in electric
furnace. Here the temperature is about 450 0 C , and due to
which wire becomes soft & then re-drawn
TYPES OF WIRE DRAWING MACHINE
SR. NO. NAME OF MACHINE DIAMETER AREA
REDUCTION(MM) REDUCTION IN(%)

1. 11 Die RBD (AL wire) 9.5-2.16 22.5

2. 9 Die RBD ( AL wire) 9.5-2.58 25

3. 9 Die RBD (Cu wire) 8-1.4 25 TO 30

4. 7 Die RBD (Fine Al/Cu 3-0.85 22

wire)

5. 17 Die (Fine Cu wire) 2.50-0.3 22.5

6. 21 Die (fine Al /CU wire) 2-0.3 22

 Line diagram of 9 die RBD

MAIN
MOTOR

DAN DAN
RAW WIRE TAKE-
- ANNEALING -
MATE DRAWING UP
CER CHAMBER CER
-RIAL CHAMBER
-1 -2

• MAIN MOTOR SPECIFICATION:

• 3-PHASE INDUCTION MOTOR
• 415 V, DELTA CONNECTED
• 160 KW, 1488 RPM
• PF = 0.86
• IP - 55
 Machine capacity
 Rated capacity :
 Motor RPM = 1488 RPM
 Driver pulley = 9”
 Driven pulley = 17.24”
 Capstan RPM = motor RPM x pulley ratio x gear ratio
= 1488 x 9/17.24 x 45/57 x37/63
= 360 RPM
 Capstan circumference = 1.72 meter
 Line speed = 619.2 MPM
 Density of copper = 8890 kg/m^3
 Required diameter = 1.8 mm
 Weight = area x density x length
= 0.785 x 0.0018^2 x 8890 x 619.2
= 13.92 kg/min
• Rated capacity
Sr. Gear RPM MPM KG/min
1 51/51 456 784.32 17.734
2 45/57 360 619.2 13.92
3 36/66 249 428.2 9.628

• Gear setting is dependent on wire size.

• Machine capacity/hr = kg/min x 60

= 9.628 x 60
= 577.68 kg / hr
• Actual production = 418 kg/hr
 Stranding machine
 The stranding of wire is done to make wire more flexible
reduce skin effect and proximity effect.
 Cold weld is used to weld two bobbins carrying aluminum
wires and electric welding is used for welding of copper
wires.
SR. NO MACHINE NAME AREA(MM2)

1 6+1(TUBLAR) 4-50
2 19 BOBIN 50-150
3 37 BOBIN 70-300
4 61 BOBIN 95-630
 61 BOBBIN STRANDING
MACHINE
GB GB MOTOR GB GB

7 12 18 24
capsta take-up
bobbin bobbin bobbin bobbin
n

• MAIN MOTOR SPECIFICATION:

• 3-PHASE INDUCTION MOTOR
• 415 V, DELTA CONNECTED
• 75 KW
• 1475 RPM
• 93% EFFICIENCY
• IP - 55
 MACHINE CAPACITY
 Gearbox is used to reduce the rpm of each cage

 Lay depends on cage rpm and line speed

 Line speed is controlled by capstan gear box

 Line speed = (cage rpm x lay of conductor)/1000

 FOR 61-BOBBIN STRANDING MACHINE

 MOTOR RPM = 1475
 CAGE RPM AT LEVER LOW = 82
 LAY OF CONDUCTOR = 220 MM
 LINE SPEED = (82 X 220)/1000

=18.04 MPM

 MACHINE HOUR RATE = 18.04 X 60 = 1082.4 m/hr = 1.0824 km/hr

 IN 8 HRS SHIFT : 1.51 X 8 = 8.659 KMS/SHIFT

 ACTUAL PRODUCTION = 3.09 KMS/SHIFT

 19 BOBIN STRANDING MACHINE

1 DIE DIE &

6 BOBIN 12 BOBIN TAKE
BOBBI HOL ROLLER CAPSTON
CAGE CAGE - UP
N DER HOLDER

• Main motor specification:

• 3-phase induction motor
• squirrel cage motor
• 415 v, delta connected
• 30 KW, 1470 rpm
• 54.5 A
• IP - 55
 MACHINE CAPACITY

 LINE SPEED = (CAGE RPM X LAY OF CONDUCTOR)/1000

 FOR 19- BOBBIN STRANDING MACHINE
 MOTOR RPM = 1470
 CAGE RPM AT LEVER HIGH = 176
 LAY OF CONDUCTOR = 140 MM
 LINE SPEED = (176 X 140)/1000

=24.72 MPM
 MACHINE HOUR RATE = 24.72 X 60 = 1483 m/hr = 1.483 km/hr

 IN 8 HRS SHIFT : 1.483 X 8 = 11.86 KMS/SHIFT

 ACTUAL PRODUCTION = 4.544 KMS/SHIFT

 INSULATION
 Extrusion process is carried out to put the insulation layer on
conductor
 Compound, in the form of pellets is fed into the back of a screw
 screw rotates in a barrel. The material advances down the screw and
is melted during the advance.
 The barrel is divided into zones which are individually temperature
controlled.
 depending on compound and extrusion parameters, barrel cooling
and even screw cooling may be required.
 Properly executed, the compound is all melted and forced through a
die-head arrangement that deposits the melt on the core being passed
through the head. This core may be a bare wire or conductor.
Extruder

MACHINE AREA

45mm extruder -I 1TO 4

45mm extruder-II 1 TO 6

60mm extruder 2.5 TO 70

120mm extruder 35 TO 630

 Extruder specification
SPEED L/D No. OF HEATING TEMP. DRIVE
(rpm) RATIO HEATING CAPACITY REG. (kw)
ZONES (kw) RANGE
(oC)
45mm 10-120 24:1 4 2.4 100-250 15
Extruder
60mm 10-100 24:1 4 2.4 100-250 30
Extruder
80mm 10-100 24:1 4 100-250 45
Extruder
90mm 10-85 24:1 5 100-250 63
Extruder
120mm 8-80 24:1 5 100-250 150
Extruder
150mm 8-72 24:1 6 70 100-275 250
Extruder
 Standard operating Procedure
Empty the hopper completely and clean it
Start the machine and drain the material which is in screw
Stop the machine
Dismantle the screw and clean it
Clean head, die, breaker plate and barrel
Mount the screw
Fit head, breaker plate, neck, tip, die on basis of job
Preheat the screw temp for XLPE

Z1 Z2 Z3 Z4 Z5 NECK HEAD DIE

170 175 180 180 185 180 185 189
Preheat the catalyst at 60 0C for 4 hours
Mix catalyst with XLPE (5%)
Mix color with mixture (0.03%-0.5%)
Load mixture in hopper Load the job
Start the extruder and do the centering until 95% is achieved
Pull the job from head and die
Connect the job with lead wire
Connect lead wire to caterpillar and close it
Start and Set the speed according to thickness
Cut joint and connect to drum Start the take up
For PVC start the vacuum pump when cable is pulled in
head
Check the thickness and vary the caterpillar speed
accordingly
For outer sheath only,
Details of printing is fed into printer initially
When cable reaches the printer start it
At the time of cutting the cable into different sizes based
on job reset the counter meter at panel and printer
 Curing
Curing process is done only in the XLPE material
The heating period to effect cross-linking is commonly
called curing
It involves cross linking of c-c bond of sioplas(pe)
compound with the help of sillane compound
Curing is the process in which insulated core is kept in
curing tank(85-90˚c)for standard time as per insulation
thickness
Curing time depends on the following factors:
Thickness of insulation
Tank temperature

Sr. Conductor area Curing time

1 <150 3 hrs
2 150 to 200 3.5 hrs
3 200 to 250 4 hrs
4 250 to 300 4.5 hrs
5 >300 6 to 8 hrs
Above given curing time is valid only if the tank temp.
is above 900C
 Laying up
Laying up is the process to construct a skeleton of 3-core cables
Lay of Laid up core is always in right hand direction
We have following laying up machine

SR.NO. MACINE AREA CORE

1 4+1 6-50 2 TO 5
2 3+1 70-630 2 TO 4
3 Drum twister 16-185 2 TO 4

4 24 Bobin 1.5-2.5 2 TO 61
5 6+1( Tubular) 1-4 2TO 7
 24 BOBBIN MACHINE

6 BOBIN DIE 18 BOBIN DIE TAPING

PAY-OFF
P HOLDER CAGE HOLDER HEAD
CAGE

TAKE-UP CAPSTON TRACKER

37KW/50HP,
1440RPM,70AMP.,415V
 MACHINE CAPACITY
 Gearbox is used to reduce the rpm of each cage

 Lay depends on cage rpm and line speed

 Line speed is controlled by capstan gear box

 Line speed = (cage rpm x lay of conductor)/1000

 FOR 24 bobbin laying up machine

 MOTOR RPM = 1450
 CAGE RPM = 60 RPM
 LAY OF CONDUCTOR = 232 MM
 LINE SPEED = (60 X 232)/1000

=13.92 MPM

 MACHINE HOUR RATE = 13.92 X 60 = 835.2 m/hr = 0.8352km/hr

 IN 8 HRS SHIFT : 0.8352 X 8 = 6.68 KMS/SHIFT

 ACTUAL PRODUCTION = 3.52 KMS/SHIFT

 6+1 TUBULAR

Main Gear- Die holder

1 bobbin 6 bobbin cage
motor box

Take Gear box

up Capstan

45KW SLIP-RING
MOTOR, 415V,1500RPM
 DRUM TWISTER
ROTATING PART

BINDE CATERPI TAKE-

RDH TPH LLAR UP
R

SECTOR SR NAME KW VOLT RPM

4 PAY-OFF
CORRECTION .
1 Motor pay off 11 415 1455
2 Caterpillar belt 15 415 1435
3 Main motor 30 415 1465
 Inner sheath
The inner sheath is required to protect the laid up core and insulation from armoring.
Compounds used PVC ST 1, PVC ST 2 and PE
Machines used for inner sheath are

The inner sheath can be either extruded or tapped

MACHINE AREA

90mm extruder 1 TO 70

80mm extruder 1 TO 50

150mm extruder 16 above

 Armoring
Armoring is done to provide mechanical strength, to carry
short circuit current and earthing of the cable.
The armoring can be done by galvanized steel strip or
galvanized steel wire, aluminum wire or copper wire
Armoring is done with left hand lay
1-core cables are always provided with non-magnetic
material armor.
Dimension as per IS : 3975
Round-wire armor is used where high tensile strength and
resistance to abrasion and mechanical damage are
desired.
 Machines used for armoring

SERIAL MACHINE TYPE AREA

NO.
1 42 BOBIN OLD GS ROUND 1.5-16
WIRE/FLATWIRE
2 42 BOBIN NEW GS ROUND 1.5-16
WIRE/FLATWIRE

3 32 BOBIN FLATWIRE 10-150

4 64 BOBIN GS ROUND 185-1000
WIRE/FLATWIRE
 64 BOBBIN ARMORING

24 42
Pay-off bobbin bobbin Taping
Die holder
cage cage head

• Main motor(Slip-ring): Take-up Capstan

• 75kw,
• 136amp,
• 1400rpm,
• 415V
 Outer sheath
 The outer sheath is required to protect the armoring and
prevent the entry of moisture
 Compounds used PVC ST 2, FRLS(H), LSZH and PE in
special cases
 The large percentage of chlorine can be released during a
fire. When combined with moisture, hydrochloric acid may
be produced. This situation highlights one of the major
problems that can result from the use of PVC.
 So FRLS is used in the outer sheath

MACHINE AREA
90mm extruder 1 TO 70
80mm extruder 1 TO 50
150mm extruder 16 AND ABOVE
Quality & Testing Department

Guided By:
Mrs. B. PANDYA
Mr. A. SINGH
Department Interface
 Functions
Regulation of the quality of raw materials, packing
materials (wooden drum), In process checks and Final
testing of finished cables.
Handling customer Inspections & preparation of
inspection reports and documents.
Hold all non-conforming products prior to dispatch.
Maintains BIS License.
 Standards
For 1.1 kv LT power & control cables, we have
following BIS License:

IS-1554/Part-1/1988 (For PVC Insulated cables)

IS-7098/Part-1/1988 (For XLPE Insulated cables)

IS-694/1990 (For House Wiring cables)

 Quality Assurance Plan
Quality is assured at every stage of cable
manufacturing.
Raw Material Testing
 Inprocess Testing
PURPOSE:
• To inspect & Test in process products as per QAP , hold all non conforming
products & release in process products for further production .
• Cost saving.
Cont..
 Final Testing
PURPOSE:
• To ensure that the final products confirm to the prescribed
standards &/or customers specifications
• To hold all non confirming finished products prior to dispatch.

TESTS COVERED:

• Routine Test
• Type Test
• Acceptance Test
• Optional Test
 Routine Test
These type of tests made by the manufacturers on all finish cable
lengths to demonstrate the integrity of cable.

Conductor Resistance Test :- This describes the energy losses due

to current flow through the cable and therefore has an important role in
determining cable temperature.

High Voltage Test (at room temperature):- The insulation

material in a cable is used to isolate the conductors from one another
and from ground as well as provide the necessary mech. Strength. It is
necessary that an evaluation of the condition of the insulation be met by
imposing a higher voltage stress for a short duration.
 Type Test
• Tests required to be made before supply on a general commercial basis a
type of cable in order to demonstrate the satisfactory performance
characteristics to meet the intended application.
 Acceptance Test
Tests carried out on samples taken from a lot for the purpose
acceptance of the lot.

• Conductor Resistance Test,

• Annealing Test (For Copper),
• Tensile Strength Test (For Aluminum),
• Wrapping Test (For Aluminum),
• Tests for Thickness of Insulation and Sheath,
• Hot Set Tests For Insulation,
• Tensile Strength and elongation at break test for Insulation & O.S

• High Voltage Test at room temperature

• Insulation Resistance (Volume Resistivity) Test
 Optional Test

•Special Tests to be carried out, when required, by

agreement between the Purchaser & Supplier.

• Cold Impact Tests for outer sheath (IS:5831/1984) and

part 21 of IS:10810) shall constitute the optional Test.
• Cold bend Tests for outer sheath (IS:5831/1984) and part
20 of IS:10810) shall constitute the optional Test.
Engineering Services
Department

GUIDED BY:
Mr. P.N. SINGH
Mr. A. PATIL
 Functions of Department
Periodic Maintenance of every machine on the
shop floor.
Attending Breakdowns
Making job orders, indents & preserving
maintenance records.
Maintenance of Electrical Sub – Station,
Utilities.
Development Activities to improve the Plant
Productivity.
 Preventive Maintenance
Yearly preventive maintenance schedule is prepared for
all machines.
As per yearly schedule, monthly preventive schedule is
made.
As per the schedule & availability of machine,
Department attends to the machines & undertakes
activities listed in PM checklist.
Necessary machine modifications are done in
consultation with respective HOD’s.
Records of inspections carried out by external agencies
are maintained in Engineering Department.
 Breakdown Maintenance
• In case of any machine breakdown, the concerned dept.
informs the Engineering Dept.
• The Dept. analyzes the nature of breakdown & takes
necessary action.
• The required spare parts are taken from the stores.
• Incase the spare parts are not available, the Dept. prepares
the Indent & forward it to the materials Dept.
• At the same time if possible the Dept. provide the
temporary arrangement to start the machine.
• Necessary entries regarding the breakdown are made in
Log book.
 Utilities
 HOT WATER GENERATOR • COMPRESSOR
 OUT PUT : 400000  IR1(100 Psi)
KCAL/HR  IR2(125 Psi)

 MAX. TEMP. :1400C  IR3(125Psi)

 ELGI(250 Psi)
 FUEL :HSD

• DG SETS
 WATER CHILLING PLANT  750 KVA
 COMPRESSOR  320 KVA
CAPACITY 32 KW
 TOTAL CAPACITY 40 TR • FORK LIFT &
HYDRA
Hot Water Generator
 Constructional Features
It is a fully automatic, forced circulation, coil type, water tube,
three pass, oil fired type Hot Water Generator.
It consists of two concentric helical coils which are concentric
with inner and outer jacket.
The inner coil forms the combustion chamber; the annular
space between the two coils is used as a second pass for flue
gas while space between outer coil and inner jacket is used as
third pass for flue gases.
The space between the two jackets is used for passing the air
required for the combustion.
Water is pumped and passed through outer coil & then it enters
the inner coil at the rear end and then comes out. During this ,
water is heated by flue gases.
 Fuel Modulation
Fuel modulation takes place as per the hot water temp.
which is sensed by temp. transmitter.
Depending on the HW temp. the transmitter gives
proportional current o/p which is given as i/p to a PID
controller which in turn controls the blower.
The blower receives signal to increase or decrease fuel o/p
by perfectly matching positions of fuel metering valve &
air damper till desired hot water generator is stabilized.
Whole operating sequence is controlled by the sequence
controller to which a flame sensor is also connected.
 Operating Control Procedure
Ensure water tank is fully leveled before start.
Ensure that there is no leakage of HSD/Waste oil.
Set the temperature of water to which is required to be
maintained.
Check all the safety valves and NRV’s.
Ensure all the switches are in operating position.
Ensure hot water pipelines are fully insulated.
Ensure the hot water operation is auto-cut when
temperature is maintained.
 Diesel Generator
 12 Cylinder - Kirloskar Cummins DG
 Capacity : 750 KVA , Rpm: 1500 (max)
440 v , 50 Hz , 1000 A
 Cooling: Water cooled through Cooling Tower –
Forced Draft
 Heat Exchanger: Shell & Tube Type
 Lubrication: oil ( oil sump-165 liters)
 Consumption: Diesel (3 units/litre)
 Self excited AVR used
 Miscellaneous: Vibration Damper, Turbocharger
 Work Instruction

Ensure
• water circulation pump
• proper battery connection
• optimum engine oil level
• diesel line valve in open condition
• switch in idle position
• proper coolant water level
• proper water level in cooling tank
DG Set Troubleshooting
1- 90 mm , 400 A 27- CAPACITOR, 250 A
2- 42 ARM ,200 A 28- DT ,250 A
3- LIGHTING .200 A 29- FURNACE, 32 B, 250 A
4- 6+1 ,200 A 30- 120 mm, 400A
5- DG ROOM ,400 A 31- HEAVY REW 3 , 250 A
6- 80 mm, 200 A 32- 61 B, 400 A
7- STRIP REW, 200A 33- 42 B NEW, 250 A
8- LIGHTING, 200 A 34- 6+1 TUB, 250 A
9- 72 B ARM, 200A
10- 24 B,200 A
11- 3+1, 200 A
12- TEST HOUSE, HWG, 200A
13- 4+1, 200 A
14- 37 B, 200 A
15- 19 B,WATER PUMP, 200 A
16- CAPACITOR, 200 A
17- 11 DIE RBD, 800 A
18- 150 mm, 600A
19- 9 DIE Al, 400 A
20- 9 DIE CU, 630 A
21- CAPACITOR,250 A
22- 150 mm MIXTURE, 250 A
23- EOT CRANE 15T, 250 A
24- 17 DIE CU, 250 A
25- CHILLING, 250 A
26- 60 mm, 250 A