ASHISH SHUBH

8/8/2019 ASHISH SHUBH

1/96

23RD SEPTEMBER 2010- 24TH OCTOBER 2010

KEC INTERNATIONAL LTD.(RPG CABLES)

SILVASSA

Induction Training Program


2/96

Overview

y Company profile

y Line of action

y Basic cable construction

y Planning department

y Design department

y Production department

y Testing departmenty Engineering services


3/96

KEC International ltd.

y

Kamani Engg. Corp. established for manufacture,enamelling and trading for Hollowware in 1945.

y Taken over by RPG group in 1982.

y Name changed to KEC International Ltd. in 1984.

y KEC International Ltd. took over RPG cables in 2010.y KEC today has excellent Project Management capabilities

in five major business areas:

y Power Transmission

y Power Distribution & Design Services

y Telecommunications Infrastructure

y Railway Infrastructure

y Cables Manufacturing

yWater harvesting


4/96

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.


5/96

Product Range


6/96

Products at silvassa

Power cables(1-4 cores,

10-1000mm2)

Control cables(1-61 cores,

1-10 mm2)

Special design cables(instrument

cable)


7/96

Silvassa Plant

y Departments:


8/96

Line Of Action

Customer

MARKETING

COSTING

PLANNING

ACCOUNTS

PURCHASE

PRODUCTION

Q/C TESTING

DESPATCH

CUSTOMER

DESIGN


9/96


10/96

Cont..4 Filler To provide circular shape

to cable.

Non- hygroscopic.

Compatibility with insulation& sheathing material.

5 Inner sheath To bind cores of cable

together & provide a

bedding for armor.

Good mechanical & thermal

properties.

6 armor To provide protectionagainst external mechanical

forces.

To carry current during

fault conditions.

High mechanical strength,reasonable electrical

conductivity & corrosion

resistant.

7 Outer sheath To provide external

covering & protection to

the cable.

Good mechanical & thermal

properties. Flexibility.

Fire retardant, and low smoke,

anti-termite, uv resistance


11/96

GUIDED BY:

MR.PRADEEP

Planning Department


12/96

Department Interface

PLANNING

DESIGN

MARKETING

QUALITY

PRODUCTION


13/96

Functions

y Interface between plant and marketing

y Freezing of order after technical and commercial

clearance

y

Decide delivery datey prepare production schedule for a month

y Provide raw material details to the purchase department

y keeps track of every job on the tracker

y Accordingly arrange the customer inspection date

y Dispatch


14/96

Cable Type

SR.

NO.

CONSTITUENT CODE LETTER

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)


15/96

Cable Code

y 2550-18-03-80-00

2550

Type ofcable

(A2XFY(P))

18

Voltagegrade

1.1 kv

03

Number ofcores

3 core

80

Conductorcrosssectionalarea

300 mm sq.

00

Standard ornonstandard

standard


16/96

Order confirmation number

y P 3070444

P

Party

Private

Govt.

State govt.

Export

1st digit

Region

1- baroda

2- mumbai

3- kolakata

Etc..

2nd digit

year

0- 2010

3rd digit

Insulation

2- PVC

7- XLPE

Last 4 digit

Serialcode


17/96

GROUPS AS PER CONDUCTOR AREA:

y Group 1: 1.5 mm2 to 6 mm2

y Group 2: 10 mm2 to 50 mm2

y Group3: 70 mm2 to 150 mm2

y Group4: 185 mm2

to 1000 mm2

y Group h: house wiring


18/96

Tracker

y Tracker is one of best example of MICROSOFT EXCEL

as a very effective tool in manufacturing industry.

y Tracker keeps up to date records of every raw material to

finished product.

y We manufacture 600+orders of cable in a month.

y We manufacture 400+ types of cables.

y So, it is a very tedious task to keep track of each and every

order.

y Everyone can keep a track of every work order with the help

of tracker.

y We can predict our plan of action if we are running late.


19/96

GUIDED BY:

MR. S. KADAM

Design Department


20/96


Design

Marketing

Planning

Production

QA &testing


21/96

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.


22/96

Standards

XLPE insulated PVC sheathed cables forworking voltages up to & including 1100 volt

IS 7098 (Part I)

For PVC Insulated cablesIS-1554 (Part-I)

Conductors for insulated electric cables &cords.

IS 8130

PVC insulation and sheath of electric cables.IS 5831

armoring of cables.IS -3975

There are some standards which are generally followed by the design

department on the basis of voltage grade of cable or customers

requirement.


23/96

Design of cables:

y Conductor:

y The choice of conductor material, size and design must

take following into consideration.

yAmpacity

yVoltage stress at the conductor

y Voltage regulation

y Conductor losses

y Bending radius and flexibility

y Overall economics

y Material considerations

y Mechanical properties


24/96

Material consideration

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, hard to full hard 2.828

Sodium 4.3

Nickel 7.8

Resistivity of metal at 20 0C


25/96

y Large size of solid conductors becomes to rigid to form,

install and terminate.y In large size of solid conductor AC resistance is increased

due to skin effect and proximity.

y Stranding becomes solution to these problems.

y Types of stranding :y Concentric stranding

y Compressed stranding

y Compact stranding

y Bunch stranding

y Rope stranding

y Sector conductor

y Segmental conductor

y Annular conductor

y

Unilay conductor


26/96

y Insulation

y Properties required

y Low dielectric constant

y Low power factor

y High dielectric strength

y Moisture resistance

y

High resistance to chemical and solventsy Materials

Polymer type Properties

LDPE Low dielectric loss

Moisture sensitiveXLPE Slightly higher losses vs. PE

Age better then PE

PVC Must contain plasticizer for

flexibility

Higher losses


27/96

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

20 0C

>10^15 >10^15 >10^13

Dielectric strength

KV/mm

50 50 20 to 35


28/96

y Armoring

y Properties requiredy Reasonable conductivity

y Mechanical strength

y Flexible

y Materials

y G.S. flat wire

y G.S. round wire

yAluminumy Copper


29/96

INSULATION TYPE TYPE OF OUTER

SHEATH

TYPE-A(700C) ST-1(700C)

TYPE- C(850C) ST-2(90

0C)

XLPE(900C) ST-2(90

0C)

OUTER SHEATHProperties required

Good mechanical & thermal properties.

Flexibility

Fire retardant

low smoke

anti-termite uv resistance


30/96

Design calculation

y O.C. NO : P3070444

y TYPE : AX

y CABLE CODE : 2550 18 93 52 49

y CORES & CONDUCTOR AREA: 3.5C X 70MM2

y CUSTOMER NAME: ORISSA MANGANESE

y PRODUCTION PLAN: 4500 MTR

y CABLE CONSTRUCTION: A2XFY(P)


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WIRE DRAWING PROCESS

y

NUMBER OF WIRES ARE DECIDED BASED ON MIN WIREREQUIREMENT AS PER IS-8130/1984.

y Main conductor

y Wire diameter : 2.16 mm

y No. of wires : 19

y 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

y FOR 4.5 KMS = 175 X 4.5

= 787.5 KG

y FOR 3 CORES = 787.5 X 3

= 2362.5 KG

y Neutral conductor

y Wire diameter : 2.52 mm

y No. of wires : 7

y Weight of neutral conductor = 394.94 KG


32/96

STRANDING PROCESS

y Main conductor :

y Length required: 4.5 x 3c = 13.5 km

y Sector angle = 1000

y Depth of conductor =

= 8.95 mm

y Width of conductor =

= 13.71mm

y Neutral conductor

y Length required: 4.5 x 1c = 4.5 km

y Sector angle = 600

y Depth = 8.174 mm

y Width = 8.174 mm

deg

360

v

varea

depthvv2

sin2U


33/96

INSULATION PROCESSy XLPE insulation :

y Nominal thickness: 1.1 mm (IS : 7098/I)

y Main Core diameter:

y Area = 0.7850 X d2

D1 = 9.28 mm

y Core diameter after XLPE insulation (dc1) = 9.28 + 2 x1.1

dc1 = 11.48mm

y Total weight of main conductor = area X density X length X no. of cores

= 445.5kg

y Neutral core diameter (d2)= 6.67 mm

y Core diameter over XLPE insulation (dc2)= 6.47 mm

y Weight of XLPE for neutral conductor = 88.61 kg

y Total weight of XLPE = 445.5 + 88.61

=534.11 kg


34/96

y 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 - dt

2)

= 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


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ARMORING PROCESS

y G.S. flat strip of 1.4 mm

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

= 26.76 + (2 x 0.8)

= 28.37mm

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

=19

y 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


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OUTER SHEATH

y Minimum thickness of the outer sheath = 1.56 mm

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

=31.48 mm

y Area of outer sheath = 146.63 mm2

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

= 996.38 kg


37/96

GUIDED BY:MR. UMESH CHANDRA

MR. L.K.MISHRA

MR. YADAV

Production Department


38/96


PRODUCTION

PLANNING

DESIGN

TESTING


39/96

Functions

y Prepares master production schedule for a month

y Raw material requisition

y Prepare job cards from manufacturing specificationy Prepare job process sheet

y Update daily production shift wise in tracker

y Coordination with maintenance department

y Coordination of man, machine, material.


40/96

Basic Process Flowchart

Wire

drawingAnnealing Redrawing Stranding

Insulation

Laying Up

1 core

Multicore

Inner

Sheath

armoringOuter

Sheath

Final

TestingDispatch

Raw

Materials

inspection

curing XLPE

PVC


41/96

Machine layout

Plant 1

Sr. Name

1 11-die Al

2 9-die Cu

3 9-die Al

4 17-die fine Cu

5 7-die fine Al

6 19 bobbin

7 Winding m/c

8 Winding m/c

9 Winding m/c

10 42 bobbin new

11 37 bobbin

12 6+1 laying up

Sr. Name

13 Winding m/c

14 Winding m/c

15 32 bobbin

16 Annealing furnace

17 Cable rewinding

18 Cable rewinding

19 120 mm extruder

20 61 bobbin

21 Drum twister

22 Winding m/c

23 21 die Al

24 Office

25 workshop


42/96

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 old6 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


43/96

Wire Drawing

y 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.

y Here the entire process is carried out in weight and not in

meters.

y Lubrication:

-For Copper wire- Soap foam /Draw Met 44

-For Aluminum wire- Draw Met 15

y 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


44/96


45/96

Line diagram of 9 die RBD

RAW

MAT

E-

RIAL

WIRE

DRAWING

CHAMBER

DA

N-

CER-

2

DA

N-

CER-

1

ANNEALING

CHAMBER

TAKE-

UP

MAIN

MOTOR

MAIN MOTOR SPECIFICATION: 3-PHASE INDUCTION MOTOR

415 V, DELTA CONNECTED

160 KW, 1488 RPM

PF = 0.86

IP - 55


46/96

Machine capacity

y Rated capacity :y Motor RPM = 1488 RPM

y Driver pulley = 9

y Driven pulley = 17.24

y Capstan RPM = motor RPM x pulley ratio x gear ratio

= 1488 x 9/17.24 x 45/57 x37/63

= 360 RPM

y Capstan circumference = 1.72 meter

y Line speed = 619.2 MPM

y Density of copper = 8890 kg/m^3

y Required diameter = 1.8 mm

y Weight = area x density x length

= 0.785 x 0.0018^2 x 8890 x 619.2

= 13.92 kg/min


47/96

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

Rated capacity

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


48/96

Stranding machine

y The stranding of wire is done to make wire more flexible

reduce skin effect and proximity effect.

y 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


49/96

MAIN MOTOR SPECIFICATION:

3-PHASE INDUCTION MOTOR

415 V, DELTA CONNECTED

75 KW

1475 RPM

93% EFFICIENCY

IP - 55

61 BOBBIN STRANDING

MACHINE

7

bobbin

12

bobbin

24

bobbin

18

bobbincapsta

ntake-up

GB GB GB GBMOTOR


50/96

MACHINE CAPACITY

y Gearbox is used to reduce the rpm of each cage

y Lay depends on cage rpm and line speed

y Line speed is controlled by capstan gear box

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

y FOR 61-BOBBIN STRANDING MACHINE

y MOTOR RPM = 1475

y CAGE RPM AT LEVER LOW = 82

y LAY OF CONDUCTOR = 220 MM

y LINE SPEED = (82 X 220)/1000

=18.04 MPM

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

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

y ACTUAL PRODUCTION = 3.09 KMS/SHIFT


51/96

19 BOBIN STRANDING MACHINE

1

BOBBI

N

6 BOBIN

CAGE

DIE

HOL

DER

12 BOBIN

CAGE

DIE &ROLLER

HOLDE

R

CAPSTONTAKE

- UP

Main motor specification:

3-phase induction motor

squirrel cage motor

415 v, delta connected

30 KW, 1470 rpm

54.5 A

IP - 55


52/96

MACHINE CAPACITY

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

y FOR 19- BOBBIN STRANDING MACHINE

y MOTOR RPM = 1470

y CAGE RPM AT LEVER HIGH = 176


y LINE SPEED = (176 X 140)/1000

=24.72 MPM

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




53/96

INSULATION

y Extrusion process is carried out to put the insulation layer on

conductor

y Compound, in the form of pellets is fed into the back of a screw

y screw rotates in a barrel. The material advances down the screw

and is melted during the advance.y The barrel is divided into zones which are individually

temperature controlled.

y depending on compound and extrusion parameters, barrel

cooling and even screw cooling may be required.

y 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.


54/96

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


55/96

Extruder specification

SPEED

(rpm)

L/DRATIO

No. OFHEATING

ZONES

HEATINGCAPACITY

(kw)

TEMP.REG.

RANGE

(oC)

DRIVE(kw)

45mm

Extruder

10-120 24:1 4 2.4 100-250 15

60mm

Extruder

10-100 24:1 4 2.4 100-250 30

80mm

Extruder

10-100 24:1 4 100-250 45

90mm

Extruder

10-85 24:1 5 100-250 63

120mm

Extruder

8-80 24:1 5 100-250 150

150mm

Extruder

8-72 24:1 6 70 100-275 250


56/96

Standard operating Procedure

y Empty the hopper completely and clean it

y Start the machine and drain the material which is in

screw

y Stop the machine

y Dismantle the screw and clean it

y Clean head, die, breaker plate and barrel

y Mount the screw

y Fit head, breaker plate, neck, tip, die on basis of job

y Preheat the screw temp for XLPE

Z1 Z2 Z3 Z4 Z5 NECK HEAD DIE

170 175 180 180 185 180 185 189


57/96

y Preheat the catalyst at 60 0C for 4 hours

y Mix catalyst with XLPE (5%)y Mix color with mixture (0.03%-0.5%)

y Load mixture in hopper Load the job

y Start the extruder and do the centering until 95% is

achieved

y Pull the job from head and die

y Connect the job with lead wire

y Connect lead wire to caterpillar and close it

y Start and Set the speed according to thickness

y Cut joint and connect to drum Start the take up

y For PVC start the vacuum pump when cable is pulled in

head


58/96

y Check the thickness and vary the caterpillar speed

accordingly

y For outer sheath only,

y Details of printing is fed into printer initially

yWhen cable reaches the printer start it

yAt the time of cutting the cable into different sizes based

on job reset the counter meter at panel and printer


59/96

Curing

y Curing process is done only in the XLPE material

y The heating period to effect cross-linking is commonly

called curing

y It involves cross linking of c-c bond of sioplas(pe)

compound with the help of sillane compound

y Curing is the process in which insulated core is kept in

curing tank(85-90c)for standard time as per insulation

thickness


60/96

y Curing time depends on the following factors:

y Thickness of insulationy Tank temperature

y Above given curing time is valid only if the tank temp. isabove 900C

Sr. Conductor area Curing time

1 300 6 to 8 hrs


61/96

Laying up

y Laying up is the process to construct a skeleton of 3-

core cables

y Lay of Laid up core is always in right hand direction

y 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


62/96

24 BOBBIN MACHINE

P

TRACKER

TAPING

HEADDIE

HOLDER6 BOBIN

CAGE

18 BOBIN

CAGEPAY-OFFDIE

HOLDER

CAPSTONTAKE-UP

37KW/50HP,

1440RPM,70AMP.,415V


63/96

MACHINE CAPACITY

y Gearbox is used to reduce the rpm of each cage

y Lay depends on cage rpm and line speed

y Line speed is controlled by capstan gear box

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

y FOR 24 bobbin laying up machine

y MOTOR RPM = 1450

y CAGE RPM = 60 RPM


y LINE SPEED = (60 X 232)/1000

=13.92 MPM

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




64/96

6+1 TUBULAR

1

bobbin

Gear boxTake

up

45KW SLIP-RING

MOTOR, 415V,1500RPM

Main

motor

Capstan

Gear-

box6 bobbin cage Die holder


65/96

DRUM TWISTER

RDH TPHCATERP

ILLAR

BINDE

R

TAKE-

UP

4 PAY-OFF SECTORCORRECTION

ROTATING PART

SR

.

NAME KW VOLT RPM

1 Motor pay off 11 415 1455

2 Caterpillar belt 15 415 1435

3 Main motor 30 415 1465


66/96

Inner sheath

y The inner sheath is required to protect the laid up core

and insulation from armoring.

y Compounds used PVC ST 1, PVC ST 2 and PE

y

Machines used for inner sheath are

y The inner sheath can be either extruded or tapped

MACHINE AREA



150mm extruder 16 above


67/96


68/96

Machines used for armoring

SERIAL

NO.

MACHINE TYPE AREA

1 42 BOBIN OLD GS ROUND

WIRE/FLATWIRE

1.5-16

2 42 BOBIN NEW GS ROUND

WIRE/FLATWIRE

1.5-16

3 32 BOBIN FLATWIRE 10-150

4 64 BOBIN GS ROUND

WIRE/FLATWIRE

185-1000


69/96

64 BOBBIN ARMORING

Pay-off

24

bobbin

cage

42

bobbin

cage

Die holder

Capstan

Taping

head

Take-up Main motor(Slip-ring):

75kw, 136amp,

1400rpm,

415V


70/96

Outer sheath

y The outer sheath is required to protect the armoring and

prevent the entry of moisture

y Compounds used PVC ST 2, FRLS(H), LSZH and PE in

special cases

y The large percentage of chlorine can be released during a

fire. When combined with moisture, hydrochloric acid maybe produced. This situation highlights one of the major

problems that can result from the use of PVC.

y So FRLS is used in the outer sheath

MACHINE AREA



150mm extruder 16 AND ABOVE


71/96

Guided By:

Mrs. B. PANDYA

Mr. A. SINGH

Quality & Testing Department


72/96


QUALITY

PRODUCTION

DESIGN

DESPATCH

PLANNING


73/96

Functions

y Regulation of the quality of raw materials, packing

materials (wooden drum), In process checks and Final

testing of finished cables.

y Handling customer Inspections & preparation of

inspection reports and documents.

y Hold all non-conforming products prior to dispatch.

y Maintains BIS License.


74/96

Standards

For 1.1 kv LT power & control cables, we have

following BIS License:

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

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

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


75/96

Quality Assurance Plan

y Quality is assured at every stage of cable manufacturing.

ProductQuality

Incoming RawMaterialsTesting

In-processQualityChecks

FinishedGoods

Testing

Routine

Test

Type

Test

Acceptance

Test


76/96

I T i


77/96

Inprocess Testing

WIREDRAWING

DIAMETER OFWIRE

TENSILE STRENGTH &WRAPPING TEST FOR Al

ANNEALING TEST FOR Cu

STRANDING

SEQUENCE

LAY LENGTH AND DIRECTION

SURFACE FINISH

EXTRUSION

THICKNESS OF INSULATION

DIA OF INSULATION

SPARK TEST

PURPOSE:

To inspect & Test in process products as per QAP , hold all non conformingproducts & release in process products for further production .

Cost saving.


78/96


79/96


80/96

Routine Test

These type of tests made by the manufacturers on all finish cable

lengths to demonstrate the integrity of cable.

y Conductor Resistance Test :- This describes the energylosses due to current flow through the cable and therefore has an

important role in determining cable temperature.

y High Voltage Test (at room temperature):- Theinsulation 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.


81/96


82/96

Tests carried out on samples taken from a lot for the purposeacceptance 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

Acceptance Test


83/96

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.

Optional Test


84/96

GUIDED BY:

Mr. P.N. SINGH

Mr. A. PATIL

Engineering Services

Department


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Functions of Department

y Periodic Maintenance of every machine on theshop floor.

yAttending Breakdowns

y Making job orders, indents & preserving maintenance records.

y Maintenance of Electrical Sub Station, Utilities.

y Development Activities to improve the Plant

Productivity.


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Preventive Maintenance

yYearly preventive maintenance schedule is prepared forall machines.

yAs per yearly schedule, monthly preventive schedule ismade.

yAs per the schedule & availability of machine,Department attends to the machines & undertakesactivities listed in PM checklist.

y Necessary machine modifications are done inconsultation with respective HODs.

y Records of inspections carried out by external agenciesare maintained in Engineering Department.


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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 thetemporary arrangement to start the machine.

Necessary entries regarding the breakdown are made in

Log book.


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Utilities

y HOT WATER

GENERATOR

OUT PUT : 400000

KCAL/HR

MAX. TEMP. :1400C

FUEL :HSD

y WATER CHILLING PLANT

COMPRESSOR

CAPACITY 32 KW

TOTAL CAPACITY 40 TR

COMPRESSOR IR1(100 Psi)

IR2(125 Psi)

IR3(125Psi)

ELGI(250 Psi)

DG SETS 750 KVA

320 KVA

FORK LIFT &HYDRA


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Constructional Features

y It is a fully automatic, forced circulation, coil type, water tube,three pass, oil fired type Hot Water Generator.

y It consists of two concentric helical coils which are concentricwith inner and outer jacket.

y The inner coil forms the combustion chamber; the annularspace between the two coils is used as a second pass for flue gaswhile space between outer coil and inner jacket is used as thirdpass for flue gases.

y The space between the two jackets is used for passing the airrequired for the combustion.

y Water is pumped and passed through outer coil & then it entersthe inner coil at the rear end and then comes out. During this ,water is heated by flue gases.


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Fuel Modulation

y Fuel modulation takes place as per the hot water temp.which is sensed by temp. transmitter.

y 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.

y 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.

y Whole operating sequence is controlled by the

sequence controller to which a flame sensor is also

connected.


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Operating Control Procedure

y Ensure water tank is fully leveled before start.

y Ensure that there is no leakage of HSD/Waste oil.

y Set the temperature of water to which is required to be

maintained.

y Check all the safety valves and NRVs.

y Ensure all the switches are in operating position.

y Ensure hot water pipelines are fully insulated.

y Ensure the hot water operation is auto-cut whentemperature is maintained.


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Diesel Generator

y 12 Cylinder - Kirloskar Cummins DG

y Capacity : 750 KVA , Rpm: 1500 (max)

440 v , 50 Hz , 1000 A

y Cooling: Water cooled through Cooling Tower

Forced Draft

y Heat Exchanger: Shell & Tube Type

y Lubrication: oil ( oil sump-165 liters)

y Consumption: Diesel (3 units/litre)

y Self excited AVR used

y Miscellaneous: Vibration Damper, Turbocharger


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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


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DG Set Troubleshooting

Air system

Air cleaner

(leakage)

Improper airtemperature

Dirtyturbochargercompressor

Fuel system

Air leaks in

suction lines

Injector flowincorrect

Broken fuelpump drive

shaft

Lubricatingsystem

Dirty oil filter

Crankcase lowor out of oil

Wrong gradeoil for weather

conditions

Coolingsystem

Insufficient

coolant

Faultythermostat

Coolanttemperature

low

Mechanicalrepair

Flywheel

balance

Worn pistons& piston rings

Broken toothof gears

Misalignedbearings


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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

Documents

ASHISH SHUBH