PRODUCT@R.P.

G(SILVASSA)
 POWER CABLES(1-4CORES ,10-
1000MM2)

CONTROL CABLES(1-61 CORES,1-10

MM2)

SPECIAL DESIGN CABLES(INSTRUMENT

CABLE)
DEPARTMENTS AT RPG CABLES

• PLANNING AND DESIGN DEPARTMENT

• PRODUCTION DEPARTMENT
• MAINTANANCE DEPARTMENT
• QUALITY CONTROL DEPARTMENT
• HR DEPARTMENT
• PURCHASE & STORE DEPARTMENT
• LOGISTICS & DESPATCH DEPARTMENT
• FINANCE &ACCOUNTS
MACHINE LIST AT RPG CABLES,
SILVASSA
MACHINE NAME NOS.
WIRE DRAWING MACHINE 6
STRANDING MACHINE 4
LAYING UP MACHINE 5
EXTRUDER 7
ARMOURING MACHINE 5
BUNCHER 3
WIRE REWINDING MACHINE 12
CABLE REWINDING MACHINE 3
D. G sets 2(750 KVA,320KVA)
HOT WATER GENERATOR 1(400000 KCAL/HR)
CHILLING PLANT 1(40 TR)
AIR COMPRESSOR PLANT 4
FORK LIFT 2
HYDRA 1
BASIC FUNCTION OF EACH DEPARTMENT
 DESIGN
(1)STANDARD DESIGN AS PER IS
(2) NON STANDARD DESIGN AS PER CUSTOMER
REQUIREMENT

(3)SPECIAL DESIGN CABLE LIKE INSTRUMENT CABLE

• IDENTIFY THE CONSTRUCTION OF CABLE

• TYPES OF CONDUCTOR INSULATION

• ARMOURED/UN ARMOURED

• SCREENED(H.T) /UNSCREENED(L.T)
CABLE CROSS-SECTION
CUSTOMER ORDER : P 2020187

P 2 0 2 0187

PATRY CODE REGION YEAR INSULATION CUSTOMER

SERIAL NO.

CODE DESCRIPTION:

1ST LETTER - PARTY CODE FOR EXAMPLE,P - PRIVATE

1 ST DIGIT - REGION CODE FOR EXAMPLE, 2- MUMBAI ,
4- DELHI ,ETC
2ND DIGIT - YEAR FOR EXAMPLE , 0 – 2010 , 1-2011
3RD DIGIT - TYPE OF INSULATION. FOR EXAMPLE, 2 – PVC 7- XLPE
LAST 4 DIGIT - CUSTOMER SERIAL NO. FOR EXAMPLE 0187
 GENERAL CODES
 2XWY(P) , A2XWY(T), A2XFY(P), A2XFY(T) , etc.

 A2XFY(T)
A-ALUMINIUM CONDUCTOR
2X –XLPE INSULATION
F-FLAT STRIP ARMOURING
Y-PVC OUTER SHEATH
(T)- TAPPED INNER SHEATH
(P)- EXTRUDED INNERSHEATH
CABLE CONSTRUCTION :
COPPER -------

ALUMINIUM A

XLPE 2X

PVC INSULATION Y

G.S. ROUND WIRE ARMOUR W

G.S. FLAT WIRE ARMOUR F

AL ROUND ARMOUR Wa

AL FLAT ARMOUR Fa

DOUBLE FLAT STRIP FF

ARMOUR
DOUBLE ROUND WIRE WW

PVC OUTER SHEATH Y

EXTRUDED INNER SHEATH (P)

TAPPED INNER SHEATH (T)

 CABLE CODE
3078 18 04 26 41

D1 3
D2 0 FIRST 4 DIGIT: TYPE OF CABLE(D1 TO D4)
D3 7
D4 8 FOR EXAMPLE 2000-2XFY(T),
3078-YWY(P)-HRPVC

D5 1 5TH AND 6TH DIGIT: VOLTAGE GRADE

D6 8 18- 1.1 KV, 16 – 1 KV

D7 0 7TH AND 8TH DIGIT:NO. OF CORES

D8 4 03- 3 CORES, 04-4 CORES, 93 - 3.5 CORES

D9 2 9TH AND 10TH DIGIT : AREA

D10 6 26-4MM2,29-6MM2,32-10MM2

D11 4 11TH AND 12TH DIGIT :UP TO 10 MM2, 41- STRANDED & 49- SOLID
D12 1 ABOVE 10 MM2, 49- STRANDED & OTHERS NON STRANDED  
 PLAN
O.C. NO: P2020187

TYPE:CP

CABLE CODE: 3078 18 04 26 41

CORES & CONDUCTOR AREA: 4C X 4MM2

CUSTOMER NAME: MUKUND LTD

PRODUCTION PLAN: 987 MTR

CABLE CONSTRUCTION: YWY(P)- HRPVC

RAW MATERIAL

COPPER (Ø 8.1 mm) , TYPE C, ST-2, G.S.ROUND WIRE .

 WIRE DRAWING PROCESS
NUMBER OF WIRES ARE DECIDED ON THE MACHINE CAPACITY AS
WELL MIN WIRE REQUIREMENT AS PER IS.
DIA. REDUCTION: 0.85
NO OF WIRES:7
 
WEIGHT OF CONDUTCTOR= AREA X DENSITY X
COMPACTIONFACTOR
=7X 0.7850X 0.852 X 8.89X0.93
= 32.39KGS/KM
FOR 0.987 KMS = 32.82 X0.987
= 32.39 KGS
FOR 4 CORES
= 32.39X 4 = 129.58 KGS REQUIRED
 STRANDING PROCESS
LENGTH REQUIRED: 0.987 X 4C = 3.94 KMS

INSULATION PROCESS
TYPE C INSULATION
NOMINAL THICKNESS: 1 mm
CORE DIAMETER:
AREA = 0.7850 X d2
4 = 0.7850 X d2
 D1 = 2.25mm
CORE DIAMETER AFTER PVC INSULATION (D2) = 2.25 + 2 X 1
 D2 = 4.25mm
FOR 0.987 KMS = 19.99 X 0.98 7
= 19.737 KG
FOR 4C = 19.737 X 4 = 78.950 KGS
AREA OF INSULATION = 0.7850X ( D22 - D12 )
= 0.7850 X (4.252- 2.252)
= 14.49 mm2
MASS OF PVC = AREA X DENSITY OF
MATERIAL(TYPEC)
= 14.49 X 1.38
= 19.99 KG/KM
FOR 0.987 KMS = 19.99 X 0.98 7 = 19.737 KG
FOR 4C = 19.737 X 4 = 78.950 KGS

TOTAL PVC (TYPE C) MATERIAL REQUIRED = 78.950 KGS

 LAID UP PROCESS
LAID UP DIAMETER (D3) = DIAMETER OVER INSULATION X
LAYING FACTOR
= 4.85 X 2.42
D3 = 11.737 mm
FOR EXTRUDED I/SH POLYESTER TAPE IS USED FOR BINDING
PURPOSE.
 INNER SHEATH PROCESS
THICKNESS OF I/SH = 0.3 mm
DIAMETER OVER I/SH (D4) = 11.737 + 2X0.3
D4= 12.33mm

AREA OF INNER SHEATH = 0.7850X (D42 - D32)

= 0.7850 X (12.332- 11.372)
= 11.203 mm2

MASS OF INNERSHEATH = AREA X DENSITY OF PVC (ST-2)

= 11.20X 1.51
= 16.91 KG/KM

FOR 0.987 KM TOTAL WT. REQUIRED = 16.91 X 0.987

= 16.69 KGS
 ARMOURING PROCESS
G.S. ROUND WIRE OF 1.4 MM
DIAMETER AFTER ARMOURING (D5) = DIAMETER OVER I/SH + 2 X
THICKNESS
= 46.29 + (2 X 1.4)
D5 = 15.130mm
NO. OF ROUND WIRES REQUIRED
= 3.142 X DIA. ARMOURING X 90/ ARMOUR SIZE
= 3.142 X 15.130 X 0.90 / (0.7850 X1.42)
= 27.78  27
WEIGHT OF ARMOURING = AREA OF WIRE X DENSITY OF G.S.WIRE X
NO. OF WIRES
= (0.7850 X 1.42) X 7.850 X 27
= 326.10 KGS/KM

FOR 0.987 KMS WEIGT OF ARMOUR REQUIRED = 0.987 X 326.10

= 321.86 KGS
 INSULATION
INSULATION TYPE TYPE OF OUTER
SHEATH
TYPE-A ST-1
TYPE- C ST-2
XLPE ST-2

• IN SOME SPECIAL CASES OUTER SHEATH MAY BE

FR,FRLSH,LSZH.
 OUTER SHEATHING PROCESS
O/SH MATERIAL: ST -2
MINIMUM THICKNESS OF O/SH FOR ARMOURED CABLES: 1.48 mm
DIAMETER OVER O/SH(D6) = DIAMETER AFTER ARMOURING + 2 X THICKNESS

= 15.130+ 2 X 1.48
D6 =18.09 mm
AREA OF O/SH = 0.7850 X (D62 – D52)
= 0.7850X (18.092- 15.1302)
= 77.189 mm2

WEIGHT OF OUTER SHEATH= AREA OF O/SH X DENSITY

= 77.189 X 1.51
= 116.55 KGS/KM

FOR 0.987 KMS = 0.987 X 116.55

= 115.04 KGS
 
 DESIGN OF DRUM

• AS PER OUTER DIA OF CABLE, BARREL DIA IS CALCULATED.

• BARREL DIA= 12D,D IS OUTER DIA OF CABLE
• DRUM SIZE=1000*350*650

• 1)BARREL

• 2)FLANGE
 SUMMARY
RM REQ
SR NO. PROCESS M/C NAME RM ( KGS)

WIRE DRAWING 9 DIE RBD (CU)

1 PROCESS AND 17 DIE RBD COPPER 129.58

STRANDING
2 PROCESS 6+1 TUBLAR

INSULATION 45 MM
3 PROCESS EXTRUDER HRPVC (TYPE-C) 78.95

POLYESTER
4 LAID UP PROCESS 6+1 TUBLAR TAPE

INNER SHEATH 90 MM
5 PROCESS EXTRUDER ST-2 16.69
42 BOBBIN
ARMOURING ARMOURING
6 PROCESS MACHINE G.S.ROUND WIRE 272.722

OUTER SHEATHING 90 MM
7 PROCESS EXTRUDER ST-2 321.86
PROCESS FLOW CHART
 PRODUCTION DEPARTMENT
WIRE DRAWING
• DEFINITION:
• WIRE DRAWING IS A METAL WORKING
PROCESS USED TO REDUCE THE DIAMETER OF A WIRE BY
PULLING THE WIRE THROUGH A SINGLE OR SERIES OF
DRAWING DIES.

• DIE MATERIALS:
HIGH SPEED STEEL
TUNGSTEN CARBIDE
DIAMOND
MATERIAL FOR WIRE DRAWING:
 ALUMINUM(Ø 9.5mm)

 COPPER(Ø 8.0 mm)

 WIRE DRAWING
COOLANT:

A COOLANT IS A FLUID WHICH PREVENT ITS

OVERHEATIN,TRANSFERRING THE HEAT AND DISSIPATE IT.
TYPES OF COOLANT:

1. DRAWMET :

WIRE DRAWING OIL FORTIFIED WITH HIGH PERFORMANCE WETTING

AGENTS. THIS OIL IS SPECIALLY SUITED FOR DEEP DRAWING OF
ALUMINIUM.

PERFORMANCE BENEFITS:
 EXCELLENT COOLING ABILITY
 SUPERIOR WETTABILITY
 LESS WIRE BREAKAGE
ANNEALING PROCESS:
• ANNEALING IS A PROCESS IN WHICH WIRE DRAWING
MATERIAL IS HEATED TO A TEMP. AROUND 550-6500C AND
THEN COOLED DOWN BY MEANS OF COOLANT.

 BENEFITS OF ANNEALING:
 ELONGATION STRENGTH INCREASES

 BETTER FLEXIBILITY

 ANOTHER MAIN PART OF COPPER RBD:

 STEAM GENERATOR

 TRANSFORMER

 DANCER
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:
160 KW, 270 AMP, 1488
RPM,PF=0.86
 CONDUCTOR
 CONDUCTOR IS A SET OF WIRES BUNCHED IN A DIFFERENT
SHAPES. CURRENT RATING DEPENDS ON CONDUCTOR AREA.
AND IT IS DONE BY STRANDING PROCESS.
 TYPES OF STRANDING
 SECTOR SHAPE
 COMPACT CIRCULAR(16 – 1000 MM2)
 CIRCULAR(UP TO 10MM2)
 CLASS OF CONDUCTOR
 CLASS 1(SOLID)
 CLASS 2(STRANDED)
 AS PER IS MIN NUMBER OF WIRES ARE REQUIERED
 CLASS 5(FLEXIBLE)
 AS PER IS MAX. WIRE DIA IS MAINTAINED
C/S AREA NO.OF WIRES/WIRE DIAMETER
SOLID STRANDNED
(CLASS-1) (CLASS-2)

1.5 1.38 7/0.53

2.5 1.78 7/0.67
4 2.25 7/0.85
6 2.76 7/1.02
10 3.55 7/1.32
16 7/1.75
25 7/2.16
35 7/2.58
50 7/2.95
70 19/2.16
95 19/2.58
120 19/2.95
150 19/3.26
185 36/2.58
240 36/2.95
300 36/3.26
400 59/2.95
• 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

 STRANDING MACHINE

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
LINE DIAGRAM OF 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:

40HP/30KW, 54.5 AMP, 3-ø SQUIRREL CAGE
INDUCTION MOTOR
TOTAL POWER CONSUMED BY MACHINE:
54.5HP
 HOW TO FIND MACHINE CAPACITY?
 STRANDING MACHINE:

 BASED ON MAIN MOTOR, RPM OF CAGE IS REDUCED THROUGH GEAR BOX.

 IF WE KNOW THE CAGE RPM AND LAY OF CONDUCTOR,

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

FOR EX, 19- BOBBIN STRANDING MACHINE

MOTOR RPM = 1460

CAGE RPM AT LEVER LOW = 152

LAY OF CONDUCTOR = 166 MM

LINE SPEED = (152 X 166)/1000

=25.23 MPM
 MACHINE HOUR RATE = 25.23 X 60 = 1514 m/hr = 1.51 km/hr
 IN 8 HRS SHIFT : 1.51 X 8 = 12 KMS/SHIFT
 ACTUAL PRODUCTION = 5 KMS/SHIFT
 D.C RESISTANCE MUST BE MAINTAINED AS PER “IS”

 LAY LENGTH DEPENDS UPON THE CONDUCTOR

DIAMETER AND MACHINE CAPACITY.
 OUTER MOST LAY SHOULD BE IN RIGHT HAND
DIRECTION.
 CALCULATION OF AREA
 FOR CIRCULAR SHAPE
AREA= π/4*D2
WHERE D= DIA. OF CONDUCTOR
 FOR SHAPED CONDUCTOR
AREA= π*r2*Ѳ/360
WIDTH=2RSIN (Ѳ/2)
WHERE: R= HEIGHT OF CONDUCTOR AREA

WIDTH AND DEPTH CALCULATION FOR SHAPED CONDUCTOR

CONDUCTOR
AREA DEGREE SIN(DEGREE/2) DEPTH WIDTH

300 60 0.5 23.94261 23.94260653

300 90 0.707106781 19.54906 27.64654066

300 100 0.766044443 18.54586 28.41391101

300 120 0.866025404 16.92998 29.32358456

300 180 1 13.82327 27.64654066

 EXTRUSION
Plastic extrusion is a high volume manufacturing process in which
raw plastic material (PVC & XLPE) is melted and formed into a
continuous profile.

TYPES:
Pressure extrusion
Sleeve/tube/vaccum extrusion
 TYPES OF RAW MATERIAL
 PVC COMPOUND
 TYPE A(GENERAL PURPOSE INSULATION FOR 70˚C)
 TYPE C(HEAT RESISTANCE INSULATION FOR 85˚C)
 XLPE(SIOPLAS)(85-90˚C)
 CURING OF XLPE:
 CURING IS NECESSARY FOR PROPER CROSS LINKING .
 FOR CURING PUPOSE INULATED CONDUCTOR IS HEATED FOR 4
TO 5 HR. AT 90˚ C.
 FOR CHEKING OF PROPER CURING OF XLPE HOT SET TEST IS
DONE.
 THICKNESS OF INSULATION IS MAINTAINED AS PER IS.
 FLOWCHART

Spark
Pay-off Cooling trough Tracker voltage
tester

extruder

Printer

Take-up Caterpillar
150MM EXTRUDER

Tip
Clamp Gearbox
Clamp

Heater
Z-6(Metering zone) Z-4,Z-3,Z-2(Melting zone) Z-1(feeding zone)

Blower Z-5(Decompression zone)

Material flow
Ø=230MM PULLEY Ø=300MM
PULLEY

MOTOR
REDUCTION
GEAR,
¡=16.67
 INSULATION INNERSHEATH
MACHINE AREA MACHINE AREA
45mm extruder -I 1TO 4
90mm extruder 1 TO 70
45mm extruder-II 1 TO 6
60mm extruder 2.5 TO 70 80mm extruder 1 TO 50
120mm extruder 35 TO 630 150mm extruder 16 above

OUTERSHEATH
MACHINE AREA
90mm extruder 1 TO 70
80mm extruder 1 TO 50
150mm extruder 16 AND ABOVE
 INSULATION
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)

• IN SOME SPECIAL CASES OUTER-SHEATH MAY BE

FR,FRLSH,LSZH.
 SPECIFICATIONS
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
Extruder
90mm 10-85 24:1 5
Extruder
120mm 8-80 24:1 5
Extruder
150mm 8-72 24:1 6 70 100-275 250
Extruder
 CALCULATION
150MM EXTRUDER :

 MOTOR RPM, N = 1500

 Ø OF PULLEY(D1) = 300MM
 Ø OF GB PULLEY(D2) = 450MM
 GEAR RATIO, R = 16.67
 SCREW SPEED = N*D1/D2*R
= 60 RPM
 MATERIAL FLOW RATE: 750 KG/HR (PVC)
CONDUCTOR AREA: 3CX240 MM2
CABLE CONSTRUCTION: A2XFY(P)-FRLSH
 WEIGHT OF INNERSHEATH = AREA OF I/SH * DENSITY
= 284 KG/KM
 LINE SPEED = (MATERIAL FLOW RATE)/(WEIGHT OF
INNERSHEATH)
= 750/284 = 2.63 KM/HR
 BEFORE START
 Dismantle the screw & Check if screw & barrel is properly cleaned or not.
 Mount the screw properly.
 Selecting tip & die for desired thickness of a given area of cable.

Tip(ID) = Cable dia. + 4mm

Die(ID) = Tip (OD) + thickness*3

 Insert it in cross-head properly.

 Assemble & fit the cross-head.
 Check the temperature sensors, if they are properly placed or not(In 150mm, it is at
every 515mm of barrel).
 Check the oil circulation of the gearbox.
 Check the cooling water circulation
 Check the tension in the driving belt.
 PROCESS
Set the temperature of various zones.
Pre-heating of raw material
Raw material (mixed with catalyst, if required) is fed from a top mounted hopper.
The rotating screw forces the plastic beads forward into the barrel which is heated to the desired melting
temperature of the molten material.
A heating profile is maintained by independent PID controlled heater zones.
It keeps moving forward and reaches decompression zone.
It enters the metering zone.
Enters the cross-head through breaker plate (547 holes of ø=3.2mm)
check for eccentricity and concentricity for achieving desired thickness.
Pass the cable through extruder by hooking it with a lead wire, which is pulled by the caterpillar.
PRESSURE ADJUSTMENT OF
CYLINDERS
WEIGHT OF CABLE (kg/m) PRESSURE (bar)
2.5 1.4
5 1.6
7.5 1.75
10 1.85
12.5 2
15 2.15
17.5 2.25
20 2.4
22.5 2.60
25 2.75
 SPARK VOLTAGE TESTER
• SPARK VOLTAGE TEST DURING INSULATION IS DECIDED
AS PER “I.S.”
SR. NO. INSULATION SPARK
THICKNESS VOLTAGE(RMS
(IN MM) VALUE IN KV)
1 UP TO 1 6
2 1 TO 1.5 10
3 1.5 TO 2 15
4 2 TO 2.5 20
5 ABOVE 2.5 25

• EMBOSSING AND PRINTING IS DONE AS PER CUSTOMER

REQUIREMENT.
 LAYING-UP
Process of bunching multiple cores with appropriate tooling to form a compact circular
shaped cable.

Core sequence
Direction of lay & lay length.
Width & thickness of tape
Overlapping ratio of tape
Use of PVC fillers
 LAID 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 16-185 2 TO 4
TWISTER

4 24 BOBIN 1.5-2.5 2 TO 61

5 6+1( Tubular) 1-7 2TO 7

 DRUM TWISTER
ROTATING PART

CATERPIL
RDH TPH BINDER TAKE-UP
LAR

Main Motor: 30KW,

415V, 50HZ,
50AMP. 1465RPM
4 PAY-OFF SECTOR
Caterpillar: 15kw
CORRECTION
Take-up: 30kw
 24 BOBIN 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
 6+1 TUBLAR

1 MAIN GEAR DIE

6 BOBIN CAGE HOLDER
BOBIN MOTOR -BOX

TAK CAPSTON GEAR-

E UP BOX

45KW SLIP-RING
MOTOR, 415V,1500RPM
 ARMOURING
THE ARMOUR PROTECTS POWER CABLE AGAINST MECHANICAL DAMAGE
OR STRESS & ALSO USED FOR EARTHING PURPOSE.

 TYPES OF ARMOURING:
 FLAT STRIP ARMOURING(G.S AND ALUMINUM)
 ROUND WIRE ARMOURING(G.S,CU)
 CU TAPES (IN SPECIAL CASE)

 DIMENSION OF FLAT STRIP:

 4 X 3.4 X 0.8
 6.1 X 5.3 X 1.6

 DIAMETER OF ROUND G.S. WIRE(MM) AS PER

“IS”:1.40,1.60,2.00,2.50,2.8,3.15,6.9
 BEYOND 13MM ROUND WIRES ARE NOT ADVISABLE.
 USE OF CURVATURE IN FLATE STRIP
 DIRECTION OF LAY IN ARMOURING
 NUMBERS OF WIRES/STRIPS CAN BE CALCULATED AS UNDER:
 NO. OF FLAT STRIPS REQUIRED
= 3.142 X DIA. OVER ARMOURING X 90/ ARMOUR
SIZE
= 3.142 X 47.89 X 0.90 / (4 X 0.8)
= 42.31  42
 MACHINES@RPG,SILVASSA
SERIAL MACHINE TYPE CORE AREA
NO.
1 42 BOBIN OLD GS ROUND 2-18 1.5-16
WIRE/FLATWIRE
2 42 BOBIN NEW GS ROUND 2-18 1.5-16
WIRE/FLATWIRE

3 32 BOBIN FLATWIRE 2-5 10-150

4 64 BOBIN GS ROUND 1-5 185-1000
WIRE/FLATWIRE
 64 BOBIN ARMOURING

24 42
PAY-OFF BOBIN BOBIN DIE TAPING
CAGE CAGE HOLDER HEAD

Main motor(Slip-ring): TAKE-UP CAPSTON

75kw,136amp,1400rpm,
415V
 MAINTANANCE
 TYPES OF MAINTANANCE
 MECHANICAL
 ELECTRICAL

 ROUTINE BREAKDOWN MAINTAINANCE

 CONDITION BASED MAINTAINANCE
 PPM(PLANT PREVENTIVE MAINTAINANCE)

 MTTR(MEAN TIME TO REPAIR)

 MTBF(MEAN TIME BETWEEN FAILURE)
 UTILITIES..
 HOT WATER GENERATER
 OUT PUT : 400000 KCAL/HR
 MAX. TEMP. :1400C
 FUEL :HSD
 WATER CHILLING PLANT
 COMPRESSOR CAPACITY 32 KW
 TOTAL CAPACITY 40 TR
 COMPRESSOR
 IR1(100 CUBIC FEET METER)
 IR2(125 CFM)
 IR3(125CFM)
 ELGI(250 CFM)
 DG SETS
 750 KVA
 320 KVA
 FORK LIFT AND HYDRA
 QUALITY CONTROL

• VARIOUS TESTING EQUIPMENTS AVAILABLE

AT RPG CABLES SILVASSA 

HV test set Oxygen Index Test SET

Thermal Stability test set Smoke Density Test set
Vacuum Oven Acid Gas Emission Test set
Ageing Oven Flammability Tester
Hot Set test sets Tensile Tester 0 - 25 KN
Hot air oven Tensile Tester 50/100/250
Cold chamber Kgs
Hydraulic press Measuring Instruments
Insulation resistance test Weighing Bridge
Conductor resistance
Muffle furnace
DIFFERENT TYPE OF TESTS
 ROUTINE TEST
 TESTS MADE BY THE MANUFACTURER TO ALL FINISHED CABLE
LENGTHS TO DEMONSTRATES THE INTEGRITY OF THE CABLE
 TYPE TEST
 TEST REQUIRED TO BE MADE BEFORE SUPPLY ON A GENRAL
COMERCIAL BASIS ON A TYPE OF CABLES IN ORDER TO
DEMONSTRATE SATISFACTORY PERFORMANCE
CHARACTERISTICS TO MEET THE INTEND APPLICATION
 ACCEPTANCE TEST
 TESTS CARRIED OUT ON SAMPLES TAKEN FROM A LOT FOR
ATHE PURPOSE OF ACEPTANCE OF LOT
 OPTIONAL TEST
 SPECIAL TEST TO BE CARREIED OUT, WHEN REQUIRED BY
AGREEMENT BETWEEN THE PURCHASER AND THE SUPPLIER
 RAW MATERIAL TESTS
 ALUMINIUM
1. TENSILE STRENGTH(85-125 N/MM2)
2. CONDUCTIVITY(37.8*106 S-M-1) DIMENSION MEASUREMENTS
 COPPER ROD
1. TENSILE STRENGTH(210 N/MM2),ELONGATION(32%)
2. CONDUCTIVITY(59.6*106 S-M-1), DIMENSION MEASUREMENTS
 PVC COMPOUND
1. TENSILE STRENGTH(12.5 N/MM2) & ELONGATION AT
BREAK(125 TO 150%)
2. THERMAL STABILITY
3. HARDNESS
4. SPECIFIC GRAVITY
5. VOLUME RESISTIVITY AT ROOM TEMP. AND ELIVATED TEMP.
ARMOURED WIRE
 MEASUREMENT OF DIMENSIONS
 TENSILE STRENGTH & ELONGATION AT BREAK
 TORSION TEST
 WINDING TEST
 RESISTIVITY TEST
 MASS OF ZINC COATING ON STEEL ARMOUR
 UNIFORMITY OF ZINC COATING ON STEEL
ARMOUR(DIP TEST)
 
WOODEN DRUMS
 VISUAL CHEACKING
 DIMENSION MEASURING
TYPES OF TESTS OF FINISHED
CABLES
1. CONDUCTOR RESISTANCE TEST
2. INSULATION RESISTANCE TEST
3. HIGH VOLTAGE TEST
4. SHRINKAGE TEST(XLPE,PVC)
5. HEAT SHOCK TEST(PVC)
6. HOT DEFORMATION TEST(PVC)
7. OXYGEN INDEX TEST(FR,FRLS,LSZH)
8. HOT SET TEST(XLPE)
9. WATER ABSORPTION TEST(XLPE)
11 VOLUME RESITIVITY
12 WATER ABSORPTION TEST(XLPE)
13 FLAMABILITY TEST
14 THERMAL STABILITY
15 MASS OF ZINC COATION ON STEEL ARMOUR(G.S.)
16 UNIFORMITY OF ZINC COATION ON STEEL ARMOUR(G.S.)
17 TENSILE STRENGTH (AL,CU,G.S,PVC& XLPE)
18 TORSION TEST(G.S. WIRE)
19 ANTI RODANE TURMITE TEST
 TESTS
 HEAT SHOKE TEST:

 TO FIND OUT CRACKING OF THERMOPLASTIC INSULATION & SHEATH OF

ELECTRICAL CABLE OVERHEATING.
 SIGNIFICANCE:

 DURING SERVICE OF CABLE IS OVERHEATED WHICH LEAD TO DEGRADATION

OF INSULATION .DUE TO THIS CRACKING OCCUR WHICH TENDS TO FAIL THE
CABLE.
 SAMPLE IS HEATED AT SPECIFIED TEMPERATURE AND DURATION TO
ASCERTAIN WITHSTAND ABILITY AT THAT CONDITION AND CHANGE IS
CHECKED BY VISUAL EXAMINATION.
 HOT SET TEST:

 TO DETERMINE OF ELONGATION AND PERMANENT SET UNDER LOAD

AT SPECIFIED TEMP. OF INSULATION OF ELECTRIC CABLES 
 SIGNIFICANT:

 FOR DETERMINATION WEATHER OR NOT THE DEPENDING

PROPERTIES ARE FULLY REALIZED AFTER CROSS LINKING 
 IT IS FOR 15 MIN.

 AT 200C.
 HOT DEFORMATION :

 TO DETERMINE RESISTANCE OF THERMOPLASTIC INSULATION AND

SHEATH OF ELECTRICAL CABLES TO DEFORMATION WHEN SUBJECTED
TO MECHANICAL PRESSURE AT HIGH PRESSURE
 NOT APPLICABLE FOR INSULATION OR SHEATH OF THICKNESS LESS
THAN 0.4MM 
 SIGNIFICANCE 

 THERMO PLASTIC COMPOUND TENDS TO SOFTEN WHEN MAINTAINED

AT HIGH TEMPERATURE OVER A SUFFICIENT PRESSURE  
 IN THAT CONDITION THEY ARE SUBJECTED TO MECHANICAL
PRESSURE THAN GET DEFORM AT THE LOCATION OF PRESSURE.
RESULTING IN REDUCTION IN THICKNESS.
 TENSILE STRENGTH AND ELONGATION AT BREACK OF ARMOUING
MATERIAL

 
 SIGNIFICANT:

 DURING LAYING CABLES ARE PULLED FROM ONE END ALONG TRENCHES
CABLESIN MINE SHAFT BRIDGES VERTICAL RUNS ETC CABLE BY VIRTUE OF
THEIR SUPPORTING METHODS ARE SUBJECTED TO PERMANENT STRESS
MATERIAL HAS ADEQUATE STRENGTH AND CAPACITY TO GET ELONGATED.

 CALCULATION : 

 ELONGATION AT BREAK=

GAUGE LENGTH AFTER FRACTURE – ORIGINAL GAUGE LENGTH

ORIGINAL GAUGE LENGTH

 shrinkage test:
 To determine shrinkage characteristics of thermoplastic
materials
 Significance:
 To determination shrinkage so may not cause any problem
in termination when cables gets heated due to energization
 Terminology: decrease in original length of test specimen
after heat treatment  
 No crack should found on cables after test
 PURCHASE DEPARTMENT
 MONTHLY RAW MATERIAL PLANING

 OPENING RAW MATERIAL STOCK

 CLOSING RAW MATERIAL STOCK

SUPLLIER PENDING ORDER

ORDER QUOTATION

COMPARE THE STATEMENTS

NEGOTIATION WITH SUPPLIERS

P.O(PURCHASE ORDER)

 RAW MATERIAL SCHEDULING

 STORE DEPT
 STORE INBOUND MATERIAL:

 SRN (STORE RECEIPT NUMBER)

 FINAL MATERIAL RECIEPT FROM SUPPLIER

 QUANTITY CHEACKING FOR RAW MATERIAL

 MISCELLANEOUS

 MATERIAL REJECTION

 RETURN TO SUPPLIER

 REJECTION FROM QUALITY DEPTT.

 PRODUCTION PROCESS DEPTT.

 TYPES OF RAW MATERIALS
PVC RAW MATERIAL
TYPE A
TYPE C
ST1
ST2
FR, FRLS , LSZH
SIOPLAS(XLPE)
GS ROUND WIRE
1.4 MM
1.6MM
2.0MM
2.5MM
2.8MM
3.5MM
GS FLAT STRIP
4*3.4*0.8
6.1*5.3*1.4
 COMMERCIAL DEPTT.
 INVENTRY
 SOURCING
 INVENTORY MANAGEMENT(STORE)
 TAXES
 DIRECT TAXES
 INDIRECT TAXES
 EXCISE TAX
 SALES TAX
 LOGISTIC
 DESPATCH
 INDIRECT TAXES
 CENTRAL EXCISE
 COMPULSORY ON EVERY FINISHED GOODS
 SALES TAX
 DESPATCH
 MAKING PLAN OF DESPATCH
 ISSUANCE OF CHALAN
 EXCISE INVOICE
 TEST CERTIFICATE
 WARRENTY
 REPLACEMENT POLICY
 AS PER CDD AND QAP PLANNING OF DESPATCH
 PAYMENT TERMS