Manufacturing of PVC Coated Cables

SMB PROJECTS
ABSOLUTE TECHNOLOGIES
TECHNOLOGIES
Technical
Know-how - A Gateway to Prosperity
A PROJECT REPORT
ON
MANUFACTURING OF
LT & HT PVC / XLPE CABLES
Prepared By
S.A. AZAD ( Alias Burhaan )
B.Sc. Tech ( Chem Tech ) , DNIIT, DGM, DFM,
Ex. Sr. Manager HPCL ( Project Planning)

For
Master Cables Pvt Ltd.
( Mr Abbas Quilon Kerala )
Mobile : +91 9447011052
( January 01, 2011 )
______________________________________________
Research Centre: Hira Nagar, Akola Road, Khamgaon ( M.S.) 444303-India
Phone / Fax : 91-7263 259052

Mktg. Off : 170, B Wing, Mangalwari Complex, Sadar,
NAGPUR 440 001, INDIA - Ph : +91 - 712 259 6919
Email : info@absoluteprojectreports.net , smbprojects@yahoo.co.in
MARKETING OFFICE : 7 RESIDENCY ROAD, OPP ASHOKA RESTAURANT, SADAR, NAGPUR 440 001
REGD OFF : HIRA NAGAR, AKOLA ROAD, KHAMGAON 444 303 ( M.S.) PH : 0712 2565152, Cell : +91 9860240852
SMB PROJECTS
MANUFACTURING OF
LT & HT PVC / XLPE CABLES
S.No.
CONTENTS
Page
No.
1.
INTRODUCTION
2.
MARKET POTENTIAL
3.
QUALITY STANDARDS
21
4.
BASIS & ASSUMPTIONS
50
5.
PRODUCTION & TECHNICAL
54
ASPECTS
6.
PROJECT FACILITIES
7.
CAPITAL COST
& OPERATING EXP. SUMMARY
77
90
8.
CASH FLOW & FINANCIAL ANALYSIS
93
9.
List of major Competitors
95
10.
Suppliers of Plants & Machineires
11 to 15 How to set up an Enterprise
97
98
& other relevant chapter

Last Page of the Report -------------- 107
SMB PROJECTS
1.0 INTRODUCTION
1.1 BACKGROUND :
M/s Master Cables Pvt. Ltd. is a rapidly growing progressive company
based in South India at Quilon, Kerala. The company plans to expand
and diversify its manufacturing capabilities for making LT / HT power
cables of all types including Marine cables and also explore the
possibility of entering into Control Cable / Data Cable market. The
company is looking into both the possibilities i.e either putting up
facilities in South India or in the FZE areas specially available for
industrial development in UAE.
With this back ground, the company has engaged a competent project
consultants, M/s Absolute Technologies SMB Projects of Nagpur
to carry out an exclusive and detailed techno-commercial studies, so
as to facilitate a proper investment planning and concrete decisions
making aiming to construct a most modern, technologically advanced
and cost effective manufacturing facilities either in South India or UAE.
1.2 LOCATION OF THE PROPOSED PROJECT :
A plot of land measuring 60 cents ( appx. 26,000 sq. feet ) area for
the proposed project is already acquired. The land is quite strategically
located near the Railway Station the National Highway. This gives a
distinct advantage to the proposed project as the sourcing and
procuring of raw materials from the nearby cities like Bangalore,
Hyderabad and Tuticorin , as well as from other manufacturing
locations like Mumbai is very convenient and cost effective. Moreover,
SMB PROJECTS
the finished products can be dispatched through Rail and Road

Transport and the necessary logistic infrastructure is readily available.
1.3 OTHER ADVNATAGES OF SELECTED LOCATION :
The location is in the vicinity of industrially growing area of Quilon city.
The water is abundantly available. However, the power situation is also
satisfactory, although the installation charges for the transformer
feeder lines have to be included in the initial capital expenditure. Still it
is proposed to provide UPS / DG power back up to ensure power
supply to the critical equipments and emergency lightings.
1.4 PRODUCT RANGE :
A cable is two or more wires running side by side and bonded, twisted
or braided together to form a single assembly. In mechanics cables,
otherwise known as wire ropes, are used for lifting, hauling and towing
or conveying force through tension. In electrical engineering cables
used to carry electric currents. An optical cable contains one or more
optical fibers in a protective jacket that supports the fibers.
Electrical cables may be made more flexible by stranding the wires. In
this process, smaller individual wires are twisted or braided together to
produce larger wires that are more flexible than solid wires of similar
size. Bunching small wires before concentric stranding adds the most
flexibility. Copper wires in a cable may be bare, or they may be plated
with a thin layer of another metal, most often tin but sometimes gold,
silver or some other material. Tin, gold, and silver are much less prone
to oxidation than copper, which may lengthen wire life, and makes
soldering easier. Tinning is also used to provide lubrication between
SMB PROJECTS
strands. Tinning was used to help removal of rubber insulation. Tight

lays during stranding makes the cable extensible (CBA - as in
telephone handset cords).
1.4.1 Power Cables
A high voltage cable - also called HV cable - is used for electric
power transmission at high voltage. High voltage cables of differing
types have a variety of applications in instruments, ignition systems,
AC and DC power transmission. In all applications, the insulation of the
cable must not deteriorate due to the high voltage stress, ozone
produced by electric discharges in air, or tracking. The cable system
must prevent contact of the high-voltage conductor with other objects
or persons, and must contain and control leakage current. Cable joints
and terminals must be designed to control the high-voltage stress to
prevent breakdown of the insulation. Often a high-voltage cable will
have a metallic shield layer over the insulation, connected to earth
ground and designed to equalize the dielectric stress on the insulation
layer, and to prevent shock.
High voltage cables may be any length, with relatively short cables
used in apparatus, longer cables run within buildings or as buried
cables in an industrial plant or for power distribution, and the longest
cables are often run as submarine cables under the ocean for power
transmission.
High voltage is defined as any voltage over 1000 volts. Cables for
3000 and 6000 volts exist, but the majority of cables are used from 10
kV and upward. Those of 10 to 33 kV are usually called medium
voltage cables, those over 50 kV high voltage cables.
SMB PROJECTS
Modern HV cables have a simple design consisting of few parts. A

conductor of copper or aluminum wires transports the current.
Conductor sections up to 2000 mm2 may transport currents up to 2000
amperes. The individual strands are often pre-shaped to provide a
smoother overall circumference. The insulation may consists of crosslinked polyethylene, also called XLPE. It is reasonably flexible and
tolerates operating temperatures up to 120 C. EPDM is also an
insulation.
At the inner and outer sides of this insulation, semi-conducting layers
are fused to the insulation. The function of these layers is to prevent
air-filled cavities between the metal conductors and the dielectric so
that little electric discharges can arise and endanger the insulation
material. The outer conductor or sheath serves as an earthed layer
and will conduct leakage currents if needed.
Most high voltage cables for power transmission that are currently sold
in the market are insulated by a sheath of cross-linked polyethylene
(XLPE). Some cables may have a lead or aluminium jacket in
conjunction with XLPE insulation to allow for fiber optics. Between
1960 and 1990, polymers became more widely used at distribution
voltages, mostly EPDM (ethylene propylene diene Monomer); however,
their relative unreliability, particularly early XLPE, resulted in a slow
uptake at transmission voltages. While cables of 330 kV are commonly
constructed using XLPE, this has occurred only in recent decades.
1.4.2 Categorization of Cables with respect to application :
1.
LT XLPE multi core cables, ( 1.1 to 11KV ), sizes 161000 mm2
SMB PROJECTS
2.
MV/HT XLPE multi core cables (11KV 500 KV ) upto 2000 mm2
3.
PVC/XLPE Control Cables (110V 1.1 KV) multi core upto 6 mm 2
4.
FRLS / HR PVC Copper Cables
5.
PTFE insulated wires and cables ( -65 deg C 260 deg C )
6.
PVC Copper Flexible wires
7.
Co-Axial Cables
1.4.3 Illustrative Photographs :
SMB PROJECTS
Wires & Cables in a Bundle
. Market Potential Continues
SMB PROJECTS
2.0 MARKET POTENTIAL

2.1 DEMAND SCENARIO :
The demand for power cables are inextricably intertwined with the
ower sector growth matrix. The power sector which had been
adversely affected by the global recession is now returning to the
recovery path, promising an upward demand cycle for the entire
electrical power industry where the cable & capacitor industry is no
exception. There has always been an air of apprehension surrounding
the long awaited potential demand from the power sector which did
not live up to its true expectation. Nevertheless, there is a note of
optimism with the gaining momentum in the power sector as seen
through the achievements and pro-active measures initiated by the
Government. The achievements, so far, in the 11th Plan clearly
outperforms the 10th Plan. In the generation sector, the thrust on the
Ultra Mega Power Plants (UMPPs), with further expansion plans, coal
import strategy to support thermal power stations, bulk gas allocation
made
available
to
power
sector, acceleration
on
the
pace
of
development of hydro projects, environmental imperatives driving

rapid growth in the renewable energy segment and the strategy on
energy security which is projecting sharp growth in the nuclear power,
are all seen to spur the demand growth for power cables.
In the same breath, the power transmission sector is pumping in
heavy
investments
and
vigour
by
constructing
gigantic
power
transmission super highways throughout the length and breadth of the

country to match the increasing power generation and also for
SMB PROJECTS
balancing the inter-state power demand. Not surprisingly, the rippleeffect out of this vigorous activity is boosting the demand in the subtransmission segment and distribution networks as well, which are
predominantly dependent on underground power cable links. In
overall, these pointers, gives the industry a heartwarming confidence
on a promised long-term sustainable growth of demand for power
cables.
The other infrastructural sectors like port construction, modernization
of airports, railways, mining sectors, road & real estate construction,
heavy engineering, defence, oil & petroleum plants are returning to its
vibrant expansionary phase and responding as the demand multiplier
for power cables segment.
2.2 SUPPLY SCENARIO :
Eyeing this potential growth phenomenon, some of the multinational
players have announced their plans to set up shop on the Indian shore
through mergers & acquisition and joint-ventures. Their activities are
focused on the high-end-product market segment. It is perceptible
that the centre of attention of the multinational players is the EHV
cables market segment. Despite, the competition the domestic
manufacturers will continue to enjoy the market penetration due to
their pragmatic quality and cost control as well as innovative
marketing skills. Moreover, at the same time, the atmosphere of
globalization offers the domestic manufacturers an opportunity to set
up their facilities in high growth and developing countires markets like
ME and Africa. Therefore, some of the Indian players have augmented
their capacities to take advantage of the demand growth in the country
10
SMB PROJECTS
as well as beyond the national boundaries and also upgrading

themselves in the higher level of 66kV to 132kV.
Currently, a few leading Chinese manufacturers have sprung into
action in the Indian market space. These manufacturers are pitching
their prices at competitive level to entice the customers. The Renminbi
(CNY) which strongly believed by all economies to be undervalued, is
giving the Chinese manufacturers an unfair advantage, hurting the
Indian Industry. The Industry has made a representation to the
Government to provide level playing field to the Industry. On the
whole, from the experience factor, many Indian customers have
realized that the Chinese manufactured goods, especially in power
equipments, have not yielded confidence in terms of reliability &
quality expectations which is deterrent to their market penetration
strategy.
2.3 A Survey of Trends, Innovations and Opportunities

The following report has shown some of the trends driving
wire and cable opportunities in India today. A recent study
undertaken
by
the
Indian
Electrical
&
Electronics
Manufacturers Association (which surveyed the opinions of

SEBs, large contractors and power cable manufacturers)
projected a compound annual growth rate of 15% for high
quality, low tension and high tension power cables through
2010 and beyond.
Major Uses and Applications of Wires and Cables:
Appliance wire
11
SMB PROJECTS
Automotive wire
. Power Cables
Control cables
Communication cables
Industrial and transportation cables
Plenum cables
12
SMB PROJECTS
2.3.1 Market Trends :

Red-hot economic growth, coupled with government reforms
designed to increase the availability of affordable electricity,
is presenting enormous opportunities for wire and cable
manufacturers in India. With a gross domestic product (GDP)
growth rate of 9.4% for the fiscal year 20062007, India is
the second-fastest growing major
economy in the world. Electricity is a key driver of this
growth, with demand for electrical energy now growing at
7.1% annually. To sustain the countrys economic growth, its
capacity for electricity generation needs to double to
200,000 mega-watts (MW) by 2012.
2.3.2 Two Indias
13
SMB PROJECTS
Delivering electricity where and when it is needed poses a

massive challenge for those in Indias public and private
sector power industry. While the availability of electricity has
increased dramatically since its independence in 1947,
demand has consistently outstripped supply and there is still
a serious dichotomy in the balance of supply to urban and
rural parts of India. According to the 2001 India Census,
about 56% of households have access to electricity but
urban access is at 82% while rural access is still only at 44%.
Even where electricity is available, reliability and quality are
matters of great concern. And with an estimated 1.136
billion people, annual per capita consumption of electricity
(at about 580 kWh) is among the lowest in the world.
2.3.3 Power Players
Two levels of government, state and central, are responsible
for ensuring that all citizens of India have access to reliable
and affordable electricity. Currently, the state governments
account for 52% of electrical power generation and the
central government 34%4. The bulk of the transmission and
distribution functions are managed by state utilities. An
important shift is the increasing role of the private sector.
Currently the private sector accounts for 14% of electrical
power generation, has a growing presence in distribution and
is making an entry into transmission.
14
SMB PROJECTS
2.3.4 Better cables mean better reliability

Power losses in India continue to hover far above global
standards. The vast majority of this power loss comes from
inefficient power grids. India transmission and distribution
losses are an average of 21%. Some states like Jammu and
Kashmir and Orissa have transmission and distribution losses
of more than 45%. Only 10% of power loss in India, on
average, is due to theft. As an international comparison
China has total losses of less than 10%5.
2.3.5 End Users Demand Long-Term Performance
One of the most significant trends in the wire and cable
industry worldwide is end user demand for technology
solutions that improve system performance, optimise system
cost, and increase the reliability of power delivery. This is
very much the case in India. To achieve these solutions,
Indian utilities are starting to work much more closely with
cable manufacturers and materials providers. As utilities
install more and more cables underground, requiring colossal
capital investments, there is an imperative to go beyond
just meeting minimum costs. It is principally because of the
increased focus on wire and cable quality and longevity that
polyethylene
insulation
is
increasingly
specified
over
incumbent materials.
15
SMB PROJECTS
2.3.6 Government reform is changing the electricity

market
The Indian governments ambitious plan (entitled Power for
all by 2012) to provide dependable power to all regions of
the country by 2012 will require a 100,000 MW increase in
generation capacity and a massive expansion of the regional
and four inter-regional distribution systems. Because energy
resources are unevenly distributed across the country,
electricity will need to be carried great distances in some
instances, which bodes well for experienced, quality focused
wire and cable manufacturers.
2.3.6.
PE
strong
in
power
cable
insulation
and
telecommunication cables
The excellent insulation characteristics of polyethylene have
made it the compound of choice in the manufacture of
communications cables, and a preferred choice in power
cable manufacturing. The type of PE most often used as an
insulation material in Indian wire and cable is cross-linkable
polyethylene or XLPE, which is very robust and has very low
water vapour transmission rate, well suited for underground
cables.
2.3.7 New Technologies
16
SMB PROJECTS
A key global trend in the wire and cable industry, also

reflected in India, is the demand for robust cable designs,
along with efforts to use combinations of power and
communication cables in the same system (duct banks, for
example) and attempts to monitor system performance
continuously. There is also increased use of cable diagnostic
techniques to manage aging cable replacement programs.
2.4 Standards
Wire and cable standards within India can be broadly
compared to International Electro-technical Commission
(IEC) standards.
Cable specifications: India
Category
Indian Specification No
Content/subject
with year
I.
Plastics
IS: 5831-1984
PVC
Insulation
PVC
Insulated
Sheath
IS: 694-1990
cables
17
SMB PROJECTS
up to 1.1 KV
IS: 1554 - (Part I) 1988
PVC
Insulated
(Heavy
duty) cables up to
1.1 KV
IS: 1554 -(Part II) 1988
PVC
Insulated
(Heavy
duty) cables up
to
from 3.3 KV-11
KV
IS: 7098- Part I-1988
XLPE insulated
with
PVC sheathed cable
up to 1.1 KV
IS: 7098- Part II-1985
XLPE insulated
with
PVC sheathed
cables
from 3.3 KV-33
KV
IS: 7098- Part III-1993
XLPE insulated
with
18
SMB PROJECTS
Thermoplastic
sheathed
cables
from
66 KV-220 KV
II.
Elastomer
IS: 6380-1984
Elastomeric
insulation
and sheath
IS: 9968-Part I 1988
Elastomeric
insulated
cables up to 1.1 KV
IS: 9968-Part II 2002
Elastomeric
insulated
cables from 3.3 KV-33 KV
2.4.1 Cable application standards :
IS: 14255-1995 Aerial bunch cable up to 1.1 KV
IS: 14494-1998 Mining cables
IS: 2465-1984 Motor vehicle cables
IS: 5950-1984 Short firing cables
IS: 9857-1990 Welding cables
2.4.2 Testing Standard :
IS 10810 Different parts for different testing
19
SMB PROJECTS
2.5 Innovative Wire & Cable Solutions for India

2.5.1 For Power Cable
Power cable markets include:
Underground power cables
Overhead power cables
Urban and rural electric utilities, for power transmission
and
distribution
Industrial power cables
The
power cable compounds should conform to the
following parameters:
Increased longevity with tree retardant cross linkable
polyethylene (TR- XLPE) insulation
Improved ease of installation and better system protection
due to excellent jacketing materials
Enhanced transmission efficiency using super smooth,
extra-clean
semi-conductive
shields,
cross-linkable
polyethylene (XLPE) insulation

Greater protection because of excellent environmental
stress crack resistance (ESCR), flexibility, toughness and
excellent moisture barrier properties for jacketing
2.5.2 For Telecommunications :
The materials for telecommunication application must meet
stringent quality and performance standards. This portfolio
20
SMB PROJECTS
provides consistent products that help maximise value and

attain lower system costs for the following markets:
Copper cable for telephone and LAN applications
Fibre optic and ocean cable
Coaxial cable for television and wireless telephone
Signal/security wires Some of the benefits delivered by
telecommunications cable materials from Dow Wire & Cable
include:
Highly stabilised foam/skin twisted pair insulation system
High-speed insulation materials with excellent
surface
smoothness
Low-shrink, high-speed insulation materials for Category 5
and 6
local area network (LAN) applications
Well-established performance of low-loss physical foaming
compounds for coaxial cable applications
Die drool-resistant jacket materials with excellent balance
of physical and electrical properties and robust performance
Low shrink fibre optic cable (FOC) jacketing materials with
excellent balance of physical and electrical properties and
robust performance
Broad
range
of
coated
metals
providing
excellent
environmental and physical protection
21
SMB PROJECTS
. Quality Standards continues
3. QUALITY STANDARDS
22
SMB PROJECTS
Steel Wire Armoured (SWA) Cable

3.1 Construction of a cable :
Steel Wire Armoured Cable, commonly abbreviated as SWA, is a
hard-wearing power cable designed for the supply of mains electricity.
It is one of a number of armoured electrical cables - which include
11kV Cable and 33kV Cable - and is found in underground systems,
power networks and cable ducting.
The typical construction of an SWA Cable can be broken down as
follows:
Conductor: consists of plain stranded copper (cables are

classified to indicate the degree of flexibility. Class 2 refers to
rigid stranded copper conductors as stipulated by British
Standard BS EN 60228:2005)
Insulation: Cross-linked polyethylene (XLPE) is used in a number

of power cables because it has good water resistance and
excellent electrical properties. Insulation in cables ensures that
conductors and other metal substances do not come into contact
with each other.
Bedding: Polyvinyl chloride (PVC) bedding is used to provide a

protective boundary between inner and outer layers of the cable.
Armour: Steel wire armour provides mechanical protection,

which means the cable can withstand higher stresses, be buried
directly and used in external or underground projects. [4] The
armouring is normally connected to earth and can also be used
as the circuit protective conductor ("earth wire") for the
equipment supplied by cable.
23
SMB PROJECTS
Sheath: a black PVC sheath holds all components of the cable

together and provides additional protection from external
stresses.
The PVC version of SWA Cable, described above, meets the

requirements of both British Standard BS5467 and International
Electrotechnical Commission standard IEC 60502. It is known as SWA
BS5467 Cable and it has a voltage rating of 600/1000V.
SWA Cable can be referred to more generally as Mains Cable,
Armoured Cable, Power Cable and Booklet Armoured Cable. The name
Power Cable, however, applies to a wide range of cables including
6381Y, NYCY, NYY-J and 6491X Cable.
During the development of the HV insulation, which has taken about
half a century, two characteristics proved to be paramount. First, the
introduction of the semiconducting layers. These layers must be
absolutely smooth, without even protrusions as small as some
microns. Further the fusion between the insulation and these layers
must be absolute;[6] any fission, air-pocket or other defect - of the
same micro-dimensions as above - is detrimental for the breakdown
characteristics of the cable.
Secondly, the insulation must be free of inclusions, cavities or other
defects of the same sort of size. Any defect of these types shortens the
voltage life of the cable which is supposed to be in the order of 30
years or more.
Cooperation between cable-makers and manufacturers of materials
has resulted in grades of XLPE with tight specifications about the
number and size of foreign particles per pound or per kilogram. [8]
Packing the raw material and unloading it within a cleanroom
environment
in
the
cable-making
machines
is
required.
The
development of extruders for plastics extrusion and cross-linking has
24
SMB PROJECTS
resulted in cable-making installations[9] for making defect-free and

pure insulations
3.2 Quality Policy & Processes :
Global Competitive atmosphere, unprotected trade environment and
freedom of imports of domestic and industrial products from any part
of the World demand a perfect quality control system from material
selecting, producing, inspection, packing to after-sales service. Each
lot of the cables and wires, rather each roll of products should be
under careful quality control checks and inspection according to
relative ISO standard or customer's detailed requirements.
The project shall obtain an ISO 9001:2000 certification right from its
inception to build a brand image not only for the domestic but also for
international
market.
3.2 SPECIFICATIONS
3.2.1 Low Voltage Cables : The applicable quality standards to LT,
PVC cables are listed below with broad categorization.
Cable Types
Manufacturing Range
Relevant
Specification
PVC Power
Cables
1.5 - 300 Sq. mm.
CONF. IS : 155
Pt I / 88
PVC Control
Cables
Upto 61 Core - 300 Sq. mm
CONF. IS : 155
Pt I / 88
PVC Flexible
Cables
Upto Multi Core - 24c X 120 Sq. mm.
CONF. IS : 694 /
90
PVC House
1/18, 3/20, 7/20
Wiring Cables
AS PER BS:
2004
Telephone
Cables
CONF. ITD : 113

- B, 114 - B,
113 - C, 129 C
Flexible and Armoured
25
SMB PROJECTS
Submersible
Cables
CONF. IS 694 /
90
Upto 3c x 50 Sq. mm
Coaxial Cables RG & UR Series
CONF. BS :
2316 , ASTM,
MIL C 17
Twin Flat
Cables
CONF. IS 694 /
90
Upto 3c - 10 Sq. mm
Weather Proof
As per Customer's requirement
Cables
CONF. IS 694 /
90
Railway
Signaling
Screened &
Upto 61 Cores of 1.5 Sq. mm. 2.5 Sq. mm
Unscreened
Cables 1.1 KV
IRS : 35
IRS : 63
Heat Resisting
PVC Cable
with Al- and
Single Core upto 1000 Sq. mm.
Copper
Multicore upto 500 Sq. mm.
Conductor 1.1
KV
1S : 1554
( PART - 1 )
FRLS PVC
Single Core upto 1000 Sq. mm.
Cables 1.1 KV Multicore upto 500 Sq. mm.
1S : 1554
( PART - 1 )
Single Core upto 630 Sq. mm. 2,3 and 4 Cores upto 50 Sq. mm.,
Light Duty PVC
Flexible unsheathed upto 50 Sq. mm. And flexible PVC Insulated and IS : 694
Cables 1.1 KV
Sheathed Cables upto 50 Sq. mm.
ANY OTHER
CABLES
ANY SIZE
REQUIREMENT
AS PER
CUSTOMER
Conductors - The Conductors are made from Aluminium of H2 or H4 grade or with high conductivity
copper as per IS : 8130 - 1984. The construction of the conductor are as under :
Nominal Cross Sectional Area
Copper mm
Aluminium mm2
Construction
1.5
1.5
Solid
2.5 to 6
2.5 to 10
Solid / Stranded
10 and Above
16 and Above
Stranded
Core Identification - Cores are identified by the colour scheme of PVC insulation.
No. of Cores Colors of Cores
1.
Red, Black, Yellow or Blue.
2.
Red and Black
3.
Red, Blue and Blue.
3.5 or 4.
Red, Yellow, Blue and Black. ( Reduce neutral core in 3.5 core cable is
Black )
5.
Red, Yellow, Blue, Grey and Black.
6. and Above Two Adjacent cores (counting core and direction core) in each layer are
colored Blue & Yellow respectively and remaining cores are Grey.
26
SMB PROJECTS
3.2.2 PVC CABLES :
Other relevant standards:
1. IS - 1554 of 1988 (part-1)

2. IS - 5831 of 1984 Re-affirmed 1991
3. IS - 8130 of 1984 "
4. IS - 10810 of 1984 (Methods of test for cable) Re-affirmed 1991
5. IS 1554 of 1988
6. IS 3975 of 1979 (Test for armouring)
7. IS - 10462 of 1983 (Part-1)
8. IS - 10418 of 1982 (For wooden Drums)
4C Aluminium/Copper Conductor, PVC Insulated, Armoured, PVC Sheathed Cable

Type: AYFY/AYWY/YFY/YWY
3.3 Technical specification of armoured 1100 volts l.t.pvc

insulated twin core 2.5mm cable with round aluminium
conductor yellow sheathed.
Normally specification covers Manufacture, testing at works, supply
and delivery of armored LT PVC insulated and PVC sheathed cables, for
single or multi core 2.5mm of H2 Grade aluminum or copper
conductors
3.3.1
Climatic Conditions:
27
SMB PROJECTS
The armored L.T. PVC cables are required to be laid outdoors either for
giving power supplies to domestic and commercial consumers. The
normal climatic conditions are as under.
a) Temperature Variation : 5C to 55C
b) Relative humidity : Up to 95%
c) Altitude : 0 to 1000 Mtrs.
d) No.of tropical monsoon months : 3 (Three)
e) Max. Wind pressure : 150 Kg/cm
f) Average annual rainfall : 750/800mm
g) Average thunderstorm base : 15 Per annum.
h) Terrain : Coastal, saline, Desert, chemically polluted,
Heavily/moderately polluted and normal Atmosphere.
3.3.2
Installations:
These cables are required to be laid indoor or outdoor between LT

Distribution Poles and the consumers premises i.e. as LT overhead
lines supported between poles and houses/shops, Commercial
establishment. These cables are required to be laid overhead, hung,
expose to atmosphere in a climatic condition as maintained above
3.4
DETAILS OF ROUTINE TEST & TYPE TEST FOR PVC

CABLES :
3.4.1 ROUTINE TEST

SR NO
NAME OF TEST
CONDUCTOR RESISTANCE TEST
HIGH VOLTAGE TEST
ANY OTHER INFORMATION
3.4.2 TYPE TESTS

SR NO
NAME OF THE TEST
TENSILE TEST FOR ALUMINIUM
WRAPPING TEST (ALLUMINIUM)
CONDUCTOR RESISTANCE TEST
4.
TEST FOR ARMOUR WIRES
28
SMB PROJECTS
5.
TEST FOR THICKNESS OF INSULATION

AND SHEATH
PHYSICAL TESTS FOR INSULATION AND

SHEATH
7.
TEST FOR BLEEDING AND BLOOMING OF

PIGMENTS
INSULATION RESISTANCE TEST
HIGH VOLTAGE TEST(WATER IMMERSION)

10
FLEMIBILITY TEST
11
THERMAL STABILITY TEST
3.5 XLPE CABLES
This being the most commonly
manufactured type of cables now in vogue, it is pertinent to cover

these cables, quality and specifications in greater details.
A cross section of XLPE cable
29
SMB PROJECTS
30
SMB PROJECTS
31
SMB PROJECTS
32
SMB PROJECTS
33
SMB PROJECTS
34
SMB PROJECTS
35
SMB PROJECTS
36
SMB PROJECTS
3.2.2 High Voltage XLPE Cables :
37
SMB PROJECTS
38
SMB PROJECTS
39
SMB PROJECTS
40
SMB PROJECTS
41
SMB PROJECTS
42
SMB PROJECTS
43
SMB PROJECTS
44
SMB PROJECTS
ACSR Conductors and Technical Data

CONSTRUCTION FOR ALL ALUMINIUM CONDUCTOR STEEL REINFORCED
AS PER IS:398 (PT - I) 1996
No of wire
in
Conductor
Construction
1+6
LAY RATIO FOR EACH LAYER

6 WIRE
(ST)
6 WIRE
(AL)
8
WIRE
(AL)
12
WIRE
(AL)
14
WIRE
(AL)
18 WIRE
(AL)
20 WIRE
(AL)
24 WIRE
(AL)
10 to 14
13
1+6+12
13 to
28
10 to 14
37
1+6+12+18
13 to
28
10 to
16
10 to 14
49
1+6+12+14+20
13 to
28
10 to
17
10 to
16
10 to 14
61
1+6+12+18+24
13 to
28
10 to
17
10 to 16
10 to 14
BASIC DATA FOR ALL ALUMINIUM CONDUCTORS STEEL REINFORCED

AS PER IS 398 (PART -II): 1996
CODE
WORD
Aluminium Area
Total
Stranding and Wire
Overall
WEIGHT MASS
Resistance Ultimate
Sq mm
Sectional
Diameter
Dia.
at 20
Breaking
Area
degC
Load
Conductor Conductor (mm)
(Sq.
approx
Ohms/Km (KN)
(AL)
(ST)
mm.)
(MAX)
Nominal Sectional
NO.
DIA
NO
DIA
Total
AL.
ST.
(mm)
(mm)
Kg/Km Kg/Km Kg/Km
MOLE
10
10.60
12.37
1.50
1.50 4.50
43
29
14
2.780
3.97
ROSE
18
18.10
21.12
1.96
1.96 5.88
73
49.5
23.5
1.618
6.74
SQUIRREL
20
20.98
24.48
2.11
2.11 6.33
85
58
27
1.394
7.61
WEASEL
30
31.61
36.88
2.59
2.59 7.77
128
87
41
0.9289
11.12
RABBIT
50
52.88
61.70
3.35
3.53 10.05
214
145
69
0.5524
18.25
RACOON
80
78.83
91.97
4.09
4.09 12.27
318
215
103
0.3712
26.91
DOG
100
105.0
118.5
4.72
1.57 14.15
394
288.3 105.7 0.2792
32.41
WOLF
150
158.1
194.9
30
2.59
2.59 18.13
727
PANTHER
200
212.1
261.5
30
3.00
3.00 21.00
976
KUNDAH
400
404.1
425.2
42
3.50
1.96 26.88 1282 1119
163
0.07311
ZEBRA
420
428.9
484.5
54
3.18
3.18 28.62 1621 1182
439
0.06868 130.32
MOOSE
520
528.5
597.0
54
3.53
3.53 31.77 1998 1463
535
0.05595 159.60
MORCULLA 560
562.7
591.7
42
4.13
2.30 31.68 1781 1553
228
0.05231 120.16
438
289
0.1871
67.34
588.5 387.5 0.1390
89.67
45
88.79
SMB PROJECTS
BASIC DATA FOR ALL ALUMINIUM CONDUCTORS STEEL REINFORCED

AS PER IS 398 (PART -II): 1976
CODE
WORD
Nominal Sectional Conduct Stranding and Conduct WEIGHT MASS Resistanc Ultimat
Equivale Aluminiu
or
Wire Diameter
or
e
e
nt
m
Area
Diamete
at 20 Breakin
Copper
Area
r
degC g Load
Conducto Conduct
Area
(Ohms/K (KG)
r (AL) or (ST)
m)
NO. DIA NO DIA
Total AL. ST.
(mm
(mm
Kg/K Kg/K Kg/K (MAX)
)
)
m
m
m
GOPHER
FERRET
MINK
HORSE
BEAVER
OTTER
CAT
16
25
40
42
45
50
55
LEOPAR
D
COYOTE
80
129.70 148.40
TIGER
LYNX
LION
BEAR
GOAT
SHEEP
DEER
FLK
CAMEL
SPARRO
W
FOX
GUINEA
LARK
72
34
116 55
173 82
204 338
205 98
230 109
261 124
1.0980
0.6795
0.4565
0.3977
0.3841
0.3434
0.3020
952
1503
2207
6108
2613
2923
3324
5.28 7 1.76 15.48
493 360 133
0.2193
4137
80
128.50 151.60 26 2.54 7 1.90 15.86
521 365 156
0.2214
4638
80
128.10 161.80 30 2.36 7 2.36 16.52
604 363 241
0.2221
5758
110
179.00 226.20 30 2.79 7 2.79 19.53
844 506 338
0.1589
7950
232.50 293.90 30 3.18 7 3.18 22.26
1097 659 438
0.1223
10210
258.10 326.10 30 3.35 7 3.35 23.45
1219 734 485
0.1102
11310
140
160
25.90
41.87
63.32
71.58
74.07
82.85
94.21
30.62 6 2.36 1 2.36

49.98 6 3.00 1 3.00
73.65 6 3.66 1 3.66
116.20 12 2.75 7 2.79
87.53 6 3.99 1 3.99
97.91 6 4.22 1 4.22
111.30 6 4.50 7 4.50
400.00
462.60
529.80
588.40
537.70
39.22
30
30
30
30
54
6
3.71
3.99
4.27
4.50
3.35
2.67
7
7
7
7
7
7
3.71
3.99
4.27
4.50
3.35
2.67
7.08
9.00
10.98
13.95
11.97
12.66
13.50
185
225
260
300
300
20
316.50
366.10
419.30
465.70
464.50
33.16
25.97
27.93
29.89
31.50
30.15
8.01
22
49
125
36.21 42.92 6 2.79 7 2.79 8.37

78.56 127.20 12 2.92 7 2.92 14.60
196.10 247.80 30 2.92 7 2.92 20.44
106
171
255
542
303
339
385
1492
1726
1977
2196
1804
135
896
1036
1188
1320
1318
92
596
690
789
876
486
43
0.0898
0.0777
0.0678
0.0611
0.0612
0.8578
13780
15910
18230
20240
14750
1208
149 101 48
590 224 366
922 556 366
0.7857
0.3620
0.1451
1313
6664
8559
Packing and Marking/Embossing Requirement for PVC Cables :

The LT PVC cable shall be wound on a wooden drum of 1000 meters
length, marking should be done on the label attached to be each drum
as per Clause No.18 of IS 1554 (Part-I/1988 ).
46
SMB PROJECTS
The wooden drums shall be as per IS: 10418/1982. The outer surface
of the drums shall be painted with white Aluminum paint. Similarly, the
inside surface of the drums shall have the protective layer of
varnish/paint to protect it from white ants. The ends of the cable shall
be sealed by means of non-hydroscopic sealing materials.
3.6
IMPORTANT
TESTING
QUALITY
ASSURANCE :
3.6.1 Testing Equipment
MACHINES
USED
FOR
Suppliers
Tensile Testing Machine
: Instron Ltd.Uk
Thermo Gravimetric Analyser
: T.A. Instruments USA
Differential Scanning Calorimeter
: T.A. Instruments USA
Rheometer
: Monsanto Ltd. U.K.
Ozone Concentration Test Equipment
: Gorden Solution India
Escr Test Chember
: Davenport Ltd. Uk
Ultra Low Temp Cabinet
: Revco USA
Accelerated Weathering Tester
: Q Panel Co USA
47
SMB PROJECTS
Infrared Spectrometer
: Perkin Elmer USA
Fourier Transform Infrared Spectrometer
: Perkin Elmer USA
High Performance Liquid Chromatograph
: Perkin Elmer USA
Atomic Absorption Spectrometer
: Perkin Elmer USA
Cold Elongation Test Apparatus
: Lab Tech India
Multi Cell Air Oven
: Wallace UK
Air Oven
: Barlow Whitney UK
3.6. 2 FRLS / LSZH Test Facility

Oxygen Index Test Equipment
: Stanton Red-Croft UK
Halogen Acid Gas Evoluation Test Set
: S.A.Associate India
Swedish Chimney Test Set
: Self Fabricated
48
SMB PROJECTS
Flammability Test Set
: Sew India
Smoke Density Test Chamber
: Ceast Italy
Vertical Flame Test Apparatus
: Yarsaley UK
Toxicity Index Test Set
: Fire Testing Equipment

UK
3.6.3 Environmental Test Facility

Organic Vapour Sampler
: Enviotech Centre India
Respirable Dust Sampler
: Envirotech Centre India
Stack Sampler
: Enviotech Centre India
3.6.4 Test Equipments (Electrical Testing)

80 kV,800 kVA Series Resonance Test Set
Hipotronics
Inc. USA
Hipotronics
Inc USA
49
SMB PROJECTS
Dielect
China
Hipotronics
Inc USA
300 kV DC High Voltage Test Set
Hipotronics
Inc USA
40 kV DC High Voltage Test Set
Bicco
UK
50 kV AC Breakdown Tester
Backman
Instruments
Inc. USA
100 kV,250 Pc Partial Discharge Detector
Hipotronics
Inc.USA
Pulse Discrimination Type P. D. Detector
Hafley
Switzerland
300 kV 250 Pc Partial Discharge Detector
Hipotronics
Inc. USA
1000 kV,25 KJ Impulse Generator
Hipotronics
Test
50
SMB PROJECTS
Inc USA
2400 kV, 120 KJ Impulse Generator
Hafley
Switzerland
5 Hz To 13 Mhz Impedance Analyser
Hewlett
Packard
USA
300 Khz To 3 Ghz Networks Analyser
Hewlett
Packard
USA
65 kV DC Impulse Type Fault Locator Cum HV Tester

(Thumper)
Biddle
Instruments
USA
300 kV Schering Bridge
Tettex
Instrument
Switzerland
3.7 CERTIFICATES OF QUALITY ASSURANCE :

These types of accreditation is a must and will be done once the
production has commenced from this project, in order to maintain a
competitive edge in the cable marketing in India and abroad.
51
SMB PROJECTS
4.0 BASIS & ASSUMPTIONS

4.1 PROFILE OF PRODUCTION COMPLEX :
The project would be raised on a plot of 65,000 sq. feet area. The plot
will be taken in a proper location in Kerala State. The management is
52
SMB PROJECTS
also considering a unit in the free trade zone in UAE. An approximate

15,000 sq. feet of production shed will be fabricated for housing the
main plant and machineries. It is proposed to construct a production
administrative block of 5,000 sq. feet and a full fledged and a storage
and dispatch section of around 15,000 sq. fee area within the
boundary of the complex.
A compound wall of 8 feet height will be
constructed for security reasons. The cost of land is Rs. Appx. 400
Lakhs, which will be capitalized in the overall project cost and
proposed to be taken as Promoters Share capital. The cost of 5000 sq.
feet building, cost of production shed as well as that of boundary wall
forms the part of capital expenditure along with that of Plant and
machineries.
4.2 Production facilities :
Production facilities will be so chosen so as to cater to mainly produce
the following products range :
1. Xlpe power cable. 1.1 - 500 KV. Size : 10 sq mm to 630 sq mm
2. PVC power cable, 1.1 - 11 KV, size.
6 mm2 to 300 mm2
3. Elastomer cable : 250 V - 33 KV, size : 1 mm2 to 300 mm2

4. Control n Instument cable , all varieties : 110 V - 1.1 KV, size 1 sq
mm to 6 mm2 ( 100 cores )
The plant and machineries will consists of most modern cable making
machines and the hi-tech testing equipments comprising Wire Drawing
machines, PVC extrusion plant, armouring machine, core laying
machine, copper annealing machine, stranding machine and bunching
machine etc.
Apart from this a full fledged Q.C. Department is
proposed with all modern equipments ( see Q.A. chapter for details )
53
SMB PROJECTS
to conform to international quality standards and to obtain the ISO

9001 : 2000 certification. Power back up ( A DG set ) shall be provided
to continue production uninterruptedly during the outage or failure of
industrial power supply from the state grid, as the area is prone to
unscheduled load shedding.
4.3 WORKING :
The plant is expected to work on 3 shifts basis and for at least 330
days per year. Therefore, the required redundancy has been built in
the plant design so that spare equipments are available to ensure
continuous and un-interrupted production even when some of the
equipments are taken off from the service for routine maintenance.
4.4 Finances :
As, the project is expected to be extremely important in terms of
regional development and creating good employment potential, the
Govt. subsidies, if available have to be availed.
However, it is not
considered at present and it may add to the cash flow in future years.
In this report entire financing is assumed to be done from the
promoters sources or through non interest bearing funding through
the community members / stake holders.
4.5
Availability of raw material :
The major raw materials are Aluminum, Copper and PVC Compound.
It will be brought from the domestic bulk suppliers through road / rail
network from the main manufacturing centers like Bangalore, Chennai,
54
SMB PROJECTS
Hyderabad and Mumbai. A minimum inventory equivalent to 30 days

production shall be maintained and the bulk purchases shall be
effected to get the economy of scale and to obtain minimum cost of
production,
with
view
to
compete
with
leading
domestic
international competitors.
4.6 Availability of power & water :
While Power may be drawn from the State Grid in case of exigencies, it
is proposed to provide a suitable capacity DG set for emergency and
essential power needs in case of prolonged outages.
The water
availability may not pose any problem as the area is abundant in water
resources and the ground water availability is not a problem.
4.7 Implementation schedule :
1.
Registration & other Formalities
1 month
2.
Purchase of land
1 month
3.
Preparation of Detailed Engg & Design: 3 month
4.
Arrangement of Finances
5.
Building construction
3 months
6.
Arrangement of Power
2 month
7.
Procurement of Plant & Machinery:
4 month
8.
Erection of Plant & Machinery
3 month
9.
Appointment of staff & labor
1 month
10.
Trial production &

:
1 month
Trouble - shooting
2 month
4.7.1 CONCURRENT AND SEQUENTIAL ACTIVITIES :

55
SMB PROJECTS
Out of above listed activities, in order to minimize the overall implementation

time, the activities can be divided and pursued into following concurrent and
sequential project phases.
Phases
Group of concurrent activities
Phase I
Registration, land Acquisition, Detailed Engg.
Total
Time
And Arrangement of Finance, construction of compound
3 months
wall
Phase II Building
Construction,
Procurement
Of
Plants
&
Machineries, Arranging of Water & Power
Next 4
Supplies
months
Phase
Erection, Commissioning, Trial production, Recruitment of
Next 3
III
Manpower, Commercial Production & Marketing
months
Thus, the total time required for the commencement of commercial production:
of power and control cables and other related range of products will be around
10 months.
Production & Technical Aspects follows .
5.0 PRODUCTION & TECHNICAL ASPECTS

5.1 Construction of a Cable :
56
SMB PROJECTS
Steel Wire Armoured (SWA) Cable
Steel Wire Armoured Cable, commonly abbreviated as SWA, is a

hard-wearing power cable designed for the supply of mains electricity.
It is one of a number of armoured electrical cables - which include
11kV Cable and 33kV Cable - and is found in underground systems,
power networks and cable ducting.
The typical construction of an SWA Cable can be broken down as
follows:
Conductor: consists of plain stranded copper (cables are

classified to indicate the degree of flexibility. Class 2 refers to
rigid stranded copper conductors as stipulated by British
Standard BS EN 60228:2005)
Insulation: Cross-linked polyethylene (XLPE) is used in a number

of power cables because it has good water resistance and
excellent electrical properties. Insulation in cables ensures that
conductors and other metal substances do not come into contact
with each other.
Bedding: Polyvinyl chloride (PVC) bedding is used to provide a

protective boundary between inner and outer layers of the cable.
57
SMB PROJECTS
Armour: Steel wire armour provides mechanical protection,

which means the cable can withstand higher stresses, be buried
directly and used in external or underground projects. [4] The
armouring is normally connected to earth and can also be used
as the circuit protective conductor ("earth wire") for the
equipment supplied by cable.
Sheath: a black PVC sheath holds all components of the cable

together and provides additional protection from external
stresses.
The PVC version of SWA Cable, described above, meets the

requirements of both British Standard BS5467 and International
Electrotechnical Commission standard IEC 60502. It is known as SWA
BS5467 Cable and it has a voltage rating of 600/1000V.
SWA Cable can be referred to more generally as Mains Cable,
Armoured Cable, Power Cable and Booklet Armoured Cable. The name
Power Cable, however, applies to a wide range of cables including
6381Y, NYCY, NYY-J and 6491X Cable.
5.2
Raw Materials:
The main raw material for the proposed industry is aluminum, copper,
PVC and XLPE granules wire and special quality rubber.
However, more specific study reveals that the Raw Material

compounds required for manufacturing Wires and Cables
5.2.1 Elastomers for Wire and Cables
The
cable
manufacturers
normally
access
wide
portfolio
of
performance-enhancing elastomers: For example, a leading company

in the international market is Dow Chemical Commpany which through
its Elastomer Division, supplies the famous branded raw materials like
ENGAGE Polyolefin Elastomers, NORDEL Hydrocarbon Rubber, and
TYRIN Chlorinated Polyethylene.
58
SMB PROJECTS
ENGAGE Polyolefin Elastomers bridge the gap between rubber and

plastic.
Produced
using
Dows
INSITE
Technology,
ENGAGE
polymers can be used to modify wire and cable compounds, or act as

the primary polymer matrix. ENGAGE polymers offer exceptional
combinations
of
flexibility
and
processability,
low
density,
and
colorability.
NORDEL Hydrocarbon Rubber products set high standards in
ethylene propylene diene monomer performance. Also produced using
INSITE Technology, NORDEL improves yield, reduces scrap and
provides exceptional polymer cleanliness for use in low voltage (LV)
and medium voltage (MV) compounds, including flame retardant (FR)
compounds.
TYRIN Chlorinated Polyethylene (CPE) materials can be used in
wire and cable jacketing compounds to increase impact strength and
resistance
to
ignition,
chemicals,
heat,
low
temperatures
and
weathering. The Dow Chemical Company is a pioneer of CPE

Though, a typical manufacturer M/s Dow Chemical Companys branded
raw materials are described in the above paragraphs, just for
illustration purposes, the list is by no means comprehensive and raw
materials sourcing could be done from various manufacturers of
domestic and international repute.
CABLE
MANUFACTURING
PROCESS
59
SMB PROJECTS
Abstract:
The present invention relates
to a method for manufacturing a
cable, said cable comprising at
least one transmissive element
(3) and at least one coating
layer (100) made of a polymeric
material and arranged at a
radially outer position with
respect to the transmissive
element (3). The method comprises the steps of: a)
feeding the polymeric material to an extrusion apparatus
including an extrusion head (1), the extrusion head (1)
comprising: a male die (12); a female die (13), coaxially
arranged with respect to said male die (12); a conveying
channel (20), at least one portion of which being defined
between said male die (12) and said female die (13); and
b) controlling a cross-sectional area of said at least one
portion of the conveying channel (20) in response to a
detected quantity, said quantity being caused to vary
during the manufacturing of the cable as a function of the
actual extrusion speed. The present invention further
relates to an extrusion apparatus for carrying out said
process.
5.3 MANUFACTURING & CYCLE OF PRODUCTION

Flow chart for manufacturing process & Quality Control Checks for XLPE cables
conforming to IS : 7098 (Part - II) 85
60
SMB PROJECTS
5.3 Flow Chart for Manufacturing Process & Quality Control Checks for Cables to IS-1554 (Part - I)
61
SMB PROJECTS
62
SMB PROJECTS
63
SMB PROJECTS
64
SMB PROJECTS
65
SMB PROJECTS
66
SMB PROJECTS
67
SMB PROJECTS
CURRENT RATINGS FOR HV XLPE CABLES:
68
SMB PROJECTS
69
SMB PROJECTS
70
SMB PROJECTS
71
SMB PROJECTS
72
SMB PROJECTS
73
SMB PROJECTS
74
SMB PROJECTS
75
SMB PROJECTS
76
SMB PROJECTS
77
SMB PROJECTS
78
SMB PROJECTS
HANDLING & STORAGE PRECAUTIONS:
. Project Facilities continues
6.0 PROJECT FACILITIES

79
SMB PROJECTS
6.1 Requirement of land :

It is estimated that a 6000 sq. metere ( appx. 65,000 sq. feet ) plot
will suffice. It takes into consideration, requirement of expansion and
future diversification as well as areas that may be necessary to put up
the staff accommodation in future years depending on the HRD policy.
As covered in the Basis & Assumption chapter, it is proposed to provide
a 10000 sq. feet of production shed, 5000 sq feet of administrative
block and 10000 sq. feet of storage and dispatch area, apart from a
secured compound wall around the complex. Thus a total of 35,000 sq.
feet of constructed area will form the basic infrastructure apart from
the compound wall.
6.2 PLANT & MACHINERIES :
6.2.1 Illustrative Photos :
HIGH SPEED MIXER MACHINE
SKINNING & LINNING EXTRUDEER
80
SMB PROJECTS
PVC CABLE MAKING MACHINE
CATTER PILLAR MCHIANE
ARMOURING MACHINE
STRANDING MACHINE
DUAL WINDER MACHINE
HIGH TWIST BUNCHING MACHINE
6.3 Important Details and specifications of machines :

81
SMB PROJECTS
6.3.1 Extrusion Line

Electric wire & cable insulation sheathing stripping & skinning. For
single, two, or three layers extrusion are available by using different
cross heads. High technical industrial computer control with full
automatic operation.
Main features
High & linear outputs throughout a broad range of speeds and
pressure
Robust construction
Production flexibility over a large scope of application
Model
Max
Speed(Rpm)
(Max)
Kg /Hr.
Driven Motors
( Kw)
SIC/EL/45
150
90
20
SIC/EL/65
120
180
40
SIC/EL/80
100
280
60
SIC/EL/100
80
350
90
SIC/EL/120
80
450
130
SIC/EL/150
60
800
250
82
SMB PROJECTS
EXTRUDER MACHINE
A CLOSE VIEW
6.3.2 Armouring Machine

The machine is used for CU, Al & steel wires or flat armouring and Cuscreening
of
the
cables.
Multiwire screening of medium and high voltage conductors
Main features
Self supporting rigid rotor design
High efficiency and speed
Bobbins mounted on pintles
Line drive by A.C. or D.C. motors with electronic or mechanical
synchronization between line components.
Different breaking device for bobbins'
Centralized lubricating system for bearing
Two performance level : normal & high speed
Tandem type Stranding Cum Armouring Machines
Machines with or without back twist
MMI /PLC Equipped,optional
Taping Heads
Single or Multi cage Assembly
Easy Lay Setting
83
SMB PROJECTS
ARMOURING MACHINE
Model
Rotor
Wire Dia Speed(Rpm) Bobbin Size
(Max)
Driven
Motors
( Kw)
SMEPL/ARM/48 1-3 mm
100
450/500/560
50
SMEPL/ARM/54 1-3 mm
100
450/500/560
60
SMEPL/ARM/72 1-3 mm
80
450/500/560
100
SMEPL/ARM/96 1-3 mm
80
450/500/560
125
6.3.3 Wire Drawing Machine

Horizontal slip type tandem drawing of copper, aluminum and all alloy
aluminum rod break down.
Main features
Ring type drawing capastan are of High Carbon High Chromium
Transmission gears and bearings are enforced lubricant
Stainless Steel Covers
Automatic annealing controls and eliminated hard wire scrap
Spool wire tension is steadily controlled with dancer attachment
MMI /PLC Equipped
84
SMB PROJECTS
Dual Spoolers
Synchronized with Inline Annealers
WIRE DRAWING MACHINE
Model
Inlet Wire Outlet Wire Production

Dia
Dia
Capacity
Driven
Motors
( Kw)
SIC/RBD/13
8/9.5
1.4/1.56
25m/sec
200
SIC/IWD/17
2.6/3.0
0.5/0.8
15m/sec
40
SIC/FWD/21
1.6/1.4
0.3/0.2
20m/sec
15
6.3.4. Core Laying Up Machine

The machine is used for cabling the multi core ( 3-7 ), PVC cables,
XLPE cables with
or
without
steel
armouring.
Main features
Machine may strand the round cables with back twist and sector
cables without back twist
Line drive by A.C. / D.C motors with electronic or mechanical
Facilitated with sector correction
85
SMB PROJECTS
With or without back twist arrangement

Main shaft is supported with roller
maintenance.
MMI and PLC Equipped, optional
Easy Lay Setting
Rigid, Sun & Planetary Types
bearings
for
easy
CORE LAYING MACHINE

Model
Rotor Speed(Rpm)
Driven Motors ( Kw)
(Max)
SMEPL/CL/1250
18
60
SMEPL/CL/1600
15
75
SMEPL/CL/1800
12
90
6.3.5 Copper Annealing Machine
86
SMB PROJECTS
Pit
Pot
Type
The Traditional method of annealing through pot furnace. Various sizes
and
combinations
of
pot
and
furnaces
are
available.
Inline Resistance Annealer For All Types Of Wire Drawing
Machines
The state of the art inline annealers are developed for best annealing
output in terms of quality and production. Normally availabe for wire
size from 0.2 mm upto 2.6 mm
Off
Line
Annealer
Resistance Annealing in an offline mode is an economical way of
annealing copper. Wire Size from 0.2 mm to 4 mm
COPPER ANNEALING MACHINE

6.3.6 Rigid Stranding Machine
The machine is used for stranding CU, Al wires and conductors.
Stranding unilay and reverse concentric, round, compressed,
compacted or sector shaped ( straight or prespiralled ) as per
customer requirements
Main features
87
SMB PROJECTS
Self supporting rigid rotor design with 1+6+12+18+24+30+36

Bobbin Cage
High efficiency and speed
Bobbins mounted on pintles
Line drive by A.C. or D.C. motors with electronic or mechanical
Different braking device for bobbins
Centralized lubricating system for bearing
Disk type Pneumatic brake for Cage.
Machines with or without back twist
MMI /PLC Equipped, optional
Easy Lay Setting
RIGID STRANDING MACHINE
Model
Rotor
Wire Dia
Bobbin Size
Speed(Rpm)
Driven
Motors
( Kw)
SMEPL/RS/30
1-3.77
mm
190
500/560/630
60
SMEPL/RS/37
1-3.77
mm
190
500/560/630
60
SMEPL/RS/61
1-3.77
mm
190
500/560/630
100
SMEPL/RS/91
1-3.77
mm
190
500/560/630
130
88
SMB PROJECTS
6.3.7 Bunching Machine

Heavy duty special model Double twist bunching machine, suitable to
twist solid and cellular insulated conductors upto 0.8mm and multi
strand flexible conductors upto 5mm (4mm OD) with minimum running
tension. The Buncher is totally enclosed within Steel Structure.
Main features
Equipped with noise absorbed safety cover
All roating parts are statically and dynamically balanced
Individual motor driving system for bow, capastan and spooler.
Optimized wire path with negligible deviation angles
Energy saving and ergonomic single bow system
BUNCHING MACHINE
Model
Bobbin Dia
Wire Dia
Rotor Speed
( RPM)
Driven Motors
( Kw)
SIC/BM/630
630
1.2 mm
1600
10
SIC/BM/500
500
1 mm
1600
10
89
SMB PROJECTS
6.3.8 Takeup & Payoff

Bed sliding type, drum hanged on vertical sliding frames. Machine
suitable for medium-large size of cable pay off/take up/rewinding.
Motorize drum loading, drum lock. Drive control of wire traversing
pitch of take up and speed synchronization.
Main features
Lifting lowering and sideways movement by AC geared motor

Versatile solution for various types of installation
Torque controller provided on each geared motor
Heavy duty rigid steel structure
Multi Speed Gear Boxes
Equipped with Traversing System
Rewinding Lines equipped with Guide Rollers, Spark Testers and
Counter Meters.
TAKE UP MACHINE
90
SMB PROJECTS
Model
Drum Dia
Load Weight (Kg)
SMEPL/1250
1250
6000
SMEPL/1600
1600
8000
SMEPL/2000
2000
10000
SMEPL/2600
2600
12000
6.3.9 Testing Machines & Other Acessories

Raw-material
Control
All raw-materials undergo rigorous testing to ensure suitability of use
in
quality
products.
Process
Control
To check process variables in every step of manufacturing process.
Products
Control
The final products are tested for compliance with the relevant
international specifications.
Spark Tester
AC High Voltage Testset
Tensile Testing Machine
AC High Voltage Testset
91
SMB PROJECTS
6.4 Photographs of some of the Test Equipments :
Network Analyzer
Halogen Acid Gas Equipment
Automatic Capacitor Winding

Machine
FTIR (Polymer Identification)
Tensile Testing Machines
Atomic Absorption
Spectrometer for Metal Analysis
Other Acessories
Wire Drawing Dies
Wire Butt Welding
Cold Pressure
Electric Over-Head
92
SMB PROJECTS
Extruder Dies &
Nozzles
Machines
Welding Machine
Travelling Cranes &

Hoists
7.0 CAPITAL COST & OPERATING EXPENSES SUMMARY

7.1 CAPITAL EXPENDITURE :
7.1 Land & Building :
7.1.1
Appx. Cost of land = Rs. 11 Lakhs
7.1.2
Cost of building & sheds :
10000 sq ft of shed @ Rs. 500 / sft
= Rs. 50 L
5000 sq ft of administrative block @ Rs. 1200 / sq ft = Rs. 60 L

10,000 sq feet of storage area @ Rs. 300 / sq ft =
Total Land + Building
Rs. 30 L
Rs. 140 Lakhs
7.1.2 PLANT & MACHINERIES : ( Breakup to be revalidated )

S.
No.
Facilities /
Machines
Take up & Payoff
Mixer
Brief Specs
500 + 50
Meters
Qty / No
Est. Cost
( Rs.
Lakhs )
2
2
Extruder
Coating Extruder
5
6
7.
8.
150 kg / Hr
5 HP motor
30mm
8 heat zones
Screw & Barrel

Heat Control Panel
Stranding macines
2 sets
Steel armoured
3 sets
93
SMB PROJECTS
8
9.
machine
Isolation and
packing machine
Wrapper wires and
cable machines for
flexibles
Printing machine
for printing name
and spec
Testing
Equipments
Motors &
Electricals
2 sets
2sets
1 set
1 set
192 Lakhs
TOTAL
TOTAL FIXED CAPITAL

( LAND, BLD + P & M ) =
332 Lakhs ..(A) = 3.3 cr.
7.2 WORKING CAPITAL REQUIREMENT :

Production Program :
1. Xlpe power cable. 1.1 - 500 KV. Size : 10 sq mm to 630 sq mm
2. PVC power cable, 1.1 - 11 KV, size.
6 mm2 to 300 mm2
3. Elastomer cable : 250 V - 33 KV, size : 1 mm2 to 300 mm2

4. Control n Instument cable , all varieties : 110 V - 1.1 KV, size 1 sq
mm to 6 mm2 ( 100 cores
7.2.1 Raw Material & Consumables :
Assumptions :
CONSUMPTION OF RAW MATERIALS / MONTH : = 315 Tonnes
94
SMB PROJECTS
Break up of R / M : PVC 80 T, Cu : 75 T, Alu : 75 T, & Armour

Steel ( GI ) = 85 T
Cost of R / M : 80 x 1 + 75 x 5 + 75 x 2.5 + 85 x 1.5 = 7.7 Cr.
OTHER COSTS :
-
Power input
Advertisement & Marketing cost
General Expenditure like post, telephone, adm
As per standard norms, other cost is about 30% of total working

capital which includes raw material + other cost.
Based on this the total WC per month = 7.7 / 0.7 = 12.80 crores
The break up will be R/M = 7.7 cr and other cost = Rs. 3.3 cr
Raw Material & other costs / Month =
Rs. 11
Crore
7.2.2 Total manpower requirement :

7.2.2 Salaries and Wages of Employees Per Month
SN
Designation
No
Salary per head
Total salary
GM Production
30,000
30,000
Manager Maintenance
20,000
20,000
Accounts Clerks
8,000
24,000
Personnel Officer
15,000
15,000
Marketing Executives
15,000
45,000
Stores In-charge
8,000
16,000
Shifts Supervisors
12,000
48,000
Shifts Operators -
20
7,500
150,000
Shift Technicians
7,500
120,000
10
Security In-charge
15,000
15,000
11
Security staff
10
8,000
80,000
112,000
Perks @ 20 %
95
SMB PROJECTS
52
TOTAL
675,000
Total Working Capital = R/M + other cost + Manpower cost

7.7
+ 0.7
8.4 crores (B)
7.3 TOTAL CAPITAL REQUIREMENT ( FIXED + WORKING ) :

(A)
TOTAL CAPITAL EXPENDITURE
+ (B)
3.3 + 8.4
11.7 crores
7.4 FINANCING OF PROJECT :

To be financed from own sources, promoters equity capital as
well as interest free Qarzan Hasanah from community source.
8.0 CASH FLOW & FINANCIAL ANALYSIS

8.1 COST OF PRODUCTION for 5 years, w.r.t GRADUAL
1. GRADUAL INCREASE IN CAPACITIES & INCREASE IN
COST @ avg. 3 %
2. No of working days in a year = 300
ASSUMPTIONS :
Figs in Rs. Crores
4
5
90
100
75.7
86.7
9.2
9.5
Head / yr.
Capacity
Raw Materials
Manpower
Processing
cost & Other
exp
1
70
53.9
8.4
2
75
59.5
8.7
3
80
65.4
8.9
4.9
5.4
5.9
6.9
7.9
COST OF
PRODUCTION
67.2
73.6
80.2
91.8
104.1
96
SMB PROJECTS
8.2 FIVE YEARS CASH FLOW

Assumptions : (1) Product mix as above, equal production of
armoured and unarmoured cables upto 4 cores (2) When converted in
Tonnnes, avg daily revenue for full capacity cables works out to appx.
Rs. 42 lakhs per day.
Revenue for 300 days of production at full
capacity = 32 x 300 = Rs. 96 cr. (3) For all the range of products an
avg price of Rs. 275 350 per meter of selling price is assumed for
simplifying the financial working. (4) Selling price increases @ 3% per
year as the input cost will go up.
CASH FLOW TABLE
Figs in Rs. Crores
Head / Year
Capacity (%)
Sales ( Tons)
Sales ( Rs.Cr)
Production
cost refer
1
70
7
67.2
2
75
7.5
74.1
3
80
8
81.5
4
90
9
94.4
73.6
80.2
91.8
0.5
1.3
2.6
3.9
0.3
0.3
0.3
0.3
(0.3)
0.2
1.0
2.3
3.6
nil
0.3
0.7
1.1
67.2
5
100
10
108.0
104.1
above table
Gr. Profit
before Dep
0.0
& Tax
Dep P&M @
16.66 % ( life =
6 yrs)
Gr. Profit
0.3
after dep
Provision of
corp. tax @
97
SMB PROJECTS
30 %
Net Profit
after tax
(0.3)
0.2
0.7
1.6
2.5
8.3 FINANCIAL ANALYSIS & CONCLUSIONS :

1. The project is basically high turn over project. On an investment
of appx. Rs. 3.3 crores, an annual turnover of around Rs. 100
crores is expected to realize.
2. The project is economically attractive. Although it may just break
even in the first two years due to lower capacity production,
once the capacity utilization increases to more than 80% and
reaches 100 % by 5th year, entire investment of Rs. 3.3 crores
will be paid back.
3. If management is able to increase the capacity / marketing for
reaching full capacity at the earliest, the project will give much
faster return on investment.
4. The project is generating more than Rs. 2 crores for the
exchequer in the form of IT. The excise duty is additional
revenues for the exchequer. Therefore, it will add to the nations
GDP and hence socio-economically relevant.
5. The project does not discharge any toxic effluent or pollutes the
air in any way. Therefore, it is environmentally friendly.
9.0 LIST OF SOME EXISITNG COMPETITORS

1. Splendor Techno India Pvt. Ltd- India
Address: 5, Shantipark, Harihar Nagar, Besa, Nagpur India
Phone(s) : 91-7103-281288 Mobile : +91-9970364400 Fax(s) : -Website : http://www.splendorindia.net/
2. Capcab India Limited - India
Address: 7, Central Market, West Avenue Road., New Delhi India
98
SMB PROJECTS
Website : http://www.capcabindialtd.com/
3. Salzer Electronics Limited - India

Address: Samichetty Palayam, Coimbatore, Tamilnadu - 641047 India
Website : http://www.salzerelectonics.net/
4. Himachal Wire Industries (p) Ltd. - India
G. T. Road Damtal Distt. Kangra India
Website : http://www.himachalwire.co.in/
5. Gemscab Industries Ltd. - India
Address: 40, Rajasthan, Udyog Nagar, G. T Karnal Road, Delhi India
Website : http://www.gemscab.co.in/
6. CENTURION POWER CABLES PVT LTD.
Address: F-1775, D.S.I.D.C. Indl. ESTATE, Narela, Delhi India
Website : http://www.centurioncables.net/
7. Pioneer Industries - India
Address: 25/112, Kabeer Nagar, North Chajjupuri, Lane No. 1, Shahdra, New
Delhi India
Website : http://www.pioneerindustries.net/
8. Khandelwal Cables Ltd - India
Address: Udyog Nagar, Bansiwala, Vrindaban India
9. Mk Cable Industries - India
Address: 488/3a , Gurudwara Road Dilshad Garden., New Delhi India
Website : http://www.emmflexgroup.com/
10. Gala Plastic Products - India
99
SMB PROJECTS
Address: 28, Shreepal Industrial Estate, Chincholi Fatak, Pawan Baug Road,
Malad (w), Mumbai India
Website : http://www.endcaps.net/
10.0 LIST OF SUPPLIERS OF PLANT & MACHINERIES

1. Dharam Engg Works,
A-142, Wazirpur Industrial Area
New Delhi, Delhi - 110 052, India
Telephone: +(91)-(11)-27373236/ 27377645
2. E Quest E Technologies Pvt Ltd
Mumbai India
Contact person :
Mr Sadiqali
Lakhani / Mr
Rajendra
Bandiwadekar
Phone
91-2225274336 /
67031901
3. Pioneer Industries,
25 / 112, Kabeer Nagar, North Chajjupuri
Lane, Shahadra, New Delhi 110094,
Email :
pioneerindustries2007@rediffmail.com
4. Vikas Engg Works,

Unit No 3, Jay bharat Industrial Estate,
Ground Flour, Western Express highway,
Goregaon East, Mumbai 400 063
Ph : 022 2874 3021 Email :
vikasengg3@vsnl.net
Web : http://www.vikasextrusion.com/
100
SMB PROJECTS
. Contd 11. How To set up an Enterprise
11. HOW TO SET UP AN ENTERPRISE

11.1. DECISION TO BE AN ENTREPRENEUR:
The following two important considerations have to be immediately
addressed before starting an enterprise.
11.2 CHOOSING YOUR FORM OF BUSINESS ORGANISATION :
The business could be
proprietary, partnership or a private limited
company. If the number of share holders are more and exceed

beyond a number specified by the Company law, the company
becomes a public limited company and no more remains private
limited. Consult a chartered accountant for more information on
company formation.
11.3 MAKING A PRODUCT CHOICE
Make a careful analysis of the product or service you are choosing,
sometimes in short run, there is a shortage of a particular commodity in
the market, you may even come to know you will get almost two weeks in
advance to supply fresh stock. Does that mean you can jump into that
business. First thing in such a condition is to analyze the situation. Keep
in mind that shortages may occur due to a number of reasons and a
good entrepreneur always examine the pros and cons before setting up a
business. It may tempt you to think that perhaps you have found a good
101
SMB PROJECTS
businesses idea. But do not be easily influenced by these temporary

shortages. Carefully analyze the future demand-supply position of the
product, say for the next 3 to 5 years. Only when you are certain that the
shortage will remain there for considerable period of time and you would
be able to generate enough profits in the very first or second year of
operation and that you can produce quality item within an acceptable
pricing, then only you should venture into such a business.
There are many organizations, which are in possession of information
on business opportunities; you can contact these organizations to get
an idea about products
1. Absolute Technologies Research Center www.absoluteprojectreports.net
2. District Industries Centers
3. Centers for Entrepreneurship Development
4. Small Industry Service Institutes
5. Industrial Extensions Bureaus (These exist in several states) they are known
by such names as index, Udyog Mitra, Udyog Sahayk and so on).
6. National Industrial Development Corporation, New Delhi
7. Khadi and Village Industries Commission, New Delhi
8. Commissioner of Cottage Industries
9. Entrepreneurship Development Institute of India, Ahmedabad
10. National Institute of Entrepreneurship and Small Business Development,
New Delhi
11. National Institute of Small Industry Extension and Training, Hyderabad
This information could be in the form of:
Project profiles
Feasibility studies
Industry studies
Area development studies.
11.4
OTHER IMPORTANT DECISIONS TO BE MADE:
LOCATION OF INDUSTRY
PREPARATION OF BUSINESS PLAN

SOURCING PROCESS, RAW MATERIALS, MACHINERIES
102
SMB PROJECTS
INFRASTRUCTURE - LAND & BUILDING, WATER AND POWER

11.5
LEGAL ASPECTS TO COMPLY
* PROVISIONAL
REGISTRATION
OF
THE
UNIT
IN
THE
CONCERNED STATE / UNION TERRITORY

* DOCUMENTS
REQUIRED
FOR
REGISTRATION
ON
PROVISIONAL BASIS
* PERMISSIONS/CLEARENCES REQUIRED
12.0
CENTRAL GOVT. POLCIY INITITATIVES TO

INCREASE EXPORTS :
Since agricultural exports offer greatest potential for increasing the

farm income, tackling unemployment, earning foreign exchange, the
Govt. has been providing a thrust to agricultural exports by building
upon conducive policy environment. A number of policy changes have
been introduced to make agricultural exports more viable. Some of
the measures include:
Import of capital goods on concessional custom duty
Zero duty in case of CIF value of capital goods of Rs. 5 crores or more
for agriculture, aquaculture, horticulture, floriculture etc. with export
obligation of 6 times CIF value of CG on FOB prices or 5 times CIF
value of CG on NFE basis with 6 years period for fulfillment of export
obligation.
Permitting 50% of the production in value terms to be sold in the
Domestic Tariff area subject to positive net foreign exchange earnings.
.
Entitlement of Special Import Licnece ;

- 1 % additional SIL for export of products like fruits, vegetables,
floriculture and horticulture products provided export of these
items is more than 10% of exports during that period.
12.1 INCENTIVES & BENEFITS AVAILABLE FROM THE GOVERNMENT:
The existing procedure of issuing eligibility certificate by the District

Industries Centre and admission of claim by Maharashtra State Electricity Board will
continue.
103
SMB PROJECTS
12.2 Special Tax Concessions
The Government offers a wide range of concessions to investors in India to

promote industrial growth and exports. The important concessions include :
Deduction of preliminary and preoperative expenses in setting up a project.
Complete tax exemption for profits from exports.
Five year tax holidays within the first eight years of commercial operations for
100% EOUs and units in EPZ.
Deduction of 30% of gross total income for 10 years for new industrial
undertakings established by companies.
Deduction of capital research and development expenditure.
12.3 Relief for Foreign Nationals :

A "Short Stay" exemption applies where all the following conditions are met :
The individual is a foreign national employed by a foreign company not doing
business in India
His stay in India does not exceed 90 days in a tax year (extended to 183 days in
certain tax treaties); and
His remuneration is not deductible in arriving at his employer's Indian taxable
income.
- Foreign technicians in certain prescribed areas are eligible for a special exemption
from tax on their salary income. The tax on their salaries could be paid by their
employees without such tax being held as part of salary for tax purposes. This
special concession is available for four years and is also fully deductible for
corporate tax purpose.
Foreign nationals are exempt from tax for home leave travel benefits for
themselves and their families, provided by the employer.
12.4 SSI Regulations:
12.4.1 foreign direct investment approval policy highlights An industrial undertaking, i.e., a company with interests in
industry can invest upto 24% equity in a SSI unit.
- If the equity goes beyond 24%, the industrial unit loses its SSI
status.
- There is no restriction on the extent of equity that can be held
by a Non-resident Indian (NRI) as an individual/partner in a SSI
unit.
104
SMB PROJECTS
- Automatic approval is granted by Reserve Bank for foreign

investment upto 51% in 35 high priority industries.
- Investors need to file an application with the Reserve Bank of
India (RBI) in the prescribed format and approval is ordinarily
granted within 15 days.
- For foreign investment outside the automatic route, clearance
has to be obtained from Foreign Investment Promotion Board
(FIPB).
- Applications for setting up a 100% Export Oriented Unit are
also required to be filed with the SIA.
- For setting up an unit in an Export Processing Zone (EPZ),
application has to be filed with the Development Commissioner
of the concerned EPZ.
- Under automatic procedures, foreign technology agreements
are being permitted in respect of industries that are designated
as high priority industries.
- The use of foreign brand names and / or trade mark of goods
is
also
now
being
permitted
freely.
- To provide access to international markets, majority foreign
equity holding upto 51% equity is being permitted for
international trading companies that are primarily engaged in
export activities.
12.4.2 operating environment and taxation policies
FDI can be in the form of cash or capital goods and there is no
minimum cash requirement, Branch organisations are
permitted only in a few specified service industries such as
banking, shipping, airlines etc., or export-oriented ventures.
Certain industries, as mentioned in the industrial policy, require
license by their nature, while others require such a license only
if
located
in
the
proximity
of
a
large
city.
This licensing applies uniformly to domestic and foreign
investment.
Also certain products are reserved for the small scale sector
and large undertakings are ordinarily permitted equity
participation up to 24 percent of total shareholding in these.
There is no restrictions regarding access to domestic markets
or
user
of
foreign
brand
names.
A work-permit as such is not required for expatriate employees,
but permission to stay is required from the Government where
the period of stay is more than three months.
RBI permission is also required to employ expatriates where
remittance of salary in foreign exchange is envisaged.
105
SMB PROJECTS
12.4.3
FDI
APPROVAL
METHODOLOGY
The highlight of the policy is the promoted prducts category

(Priority Sector in FDI)where approval for up to 51% equity
investment proposals is automatic and where only an
application to the Reserve Bank of India is required. This
procedure is also applicable to investment proposals involving
trading companies and hotels and the tourism related industry.
Investment proposals involving greater than 51% equity or
involving products not in the promoted category require
approval from the Ministry of Industry through the specially
empowered Foreign Investment Promotion Board which can
negotiate terms directly on major proposals in their totality and
free
from
any
predetermined
parameters
And there are special facilities and incentives for export
oriented units and investment in units located in any of the
export
promotion
zones.
For further information regarding automatic approvals, write to
CONTROLLER
EXCHANGE
CONTROL
DEPARTMENT
RESERVE
BANK
OF
INDIA
NEW
CENTRAL
OFFICE
BUILDING
SHAHEED
BHAGAT
SINGH
ROAD
BOMBAY
400023
For proposals not coming in the automatic approval category
write to:
SECRETARY
SECRETARIAT OF INDUSTRIAL APPROVAL (SIA)
DEPARTMENT OF INDUSTRIAL APPROVAL
MINISTRY OF INDUSTRY
UDYOG BHAWAN
NEW DELHI- 110001
12.4.4 NON-RESIDENT INDIANS (NRI) INVESTMENT
A liberal policy for permitting investment of upto 100% equity

wth full repatriation facilities in industrial ventures in high
priority industries by Non-Resident Indians (NRIs) and Overseas
Corporation Bodies (OCBs) has been announced. It has also
been decided to permit 100% NRI investment with full
repatriation benefits in Export/ Trading/ Star Trading House also.
106
SMB PROJECTS
REPATRIATION OF DIVIDENDS
India permits free repatriation of profits after payment of the
applicable taxes for all approved investments other than in few
specified
industries.
In these consumer goods industries, repatriation of profits is
allowed only out of net foreign exchange earnings during an
initial period of seven years from the commencement of
production.
However, there are procedural requirements for obtaining RBI
approval for repatriation of Branch profits or dividend by an
Indian company which has more than 40 percent of equity.
On disinvestment, capital may be repatriated subject to the sale
price being considered reasonable by the RBI and payment of
applicable taxes.
12.4.5 FOREIGN INVESTMENT PROMOTION BOARD
Government of India has established a Special Empowered
Board called Foreign Investment Promotion Board in the Ministry
of Industry, to negotiate with large international firms and to
approve direct foreign investment in selected areas.
Objective
The objective of this Board will be to invite and facilitate
investment in India by international companies in projects which
are considered to be of benefit to the Indian economy and do
not fall within the parameters of the existing policy for clearance
of foreign investment proposals.
Functions
The functions of the Board shall mainly comprise: Expeditious
clearance
of
proposals;
Establishment of contact with and inviting selected international
companies to invest in India in appropriate ventures; and
To periodically review the implementation of projects cleared by
the Board. The Board will provide a single window clearance for
all aspects of projectproposals considered by it. No formal
application forms are prescribed; the entrepreneur can directly
107
SMB PROJECTS
correspond
with
12.4.6
NRI
the
Investment
Board.
Approval:
- Non-Resident Indians (NRIs) allowed to invest upto 100%

equity with full benefits of repatriation in most industry sectors.
- There is no restriction on the extent of equity that can be held
by a Non-Resident Indian (NRI) as an individual/partner in a SSI
unit.
- NRIs and Overseas Corporate Bodies (OCB) predominantly
owned by NRIs are allowed to invest upto 100% foreign equity in
high priority industries with full repatriation benefits.
- To set up large industrial ventures in products reserved for the
small scale sector, the unit has to take up a 75% export
obligation.
. Contd Factories Act
13.0 THE FACTORIES ACT

13.1 Objectives
- To ensure adequate safety measures and to promote the health
and welfare of the workers employed in factories.
- To prevent haphazard growth of factories through the provisions
related to the approval of plans before the creation of a factory.
13.2 Scope and coverage
- Regulates working condition in factories.
- Basic minimum requirements for ensuring safety, health and
welfare of
workers.
- Applicable to all workers.
- Applicable to all factories using power and employing 10 or more
workers, and if not using power, employing 20 or more workers on
any day of the preceding 12 months.
108
SMB PROJECTS
13.3 Main provisions

- Compulsory approval, licencing and registration of factories.
- Health measures.
- Safety measures.
- Welfare measures.
- Working hours.
- Employment of women and young persons.
- Annual leave provision.
- Accident and occupational diseases.
- Dangerous operations.
- Penalties.
- Obligations and rights of employees. when to consult and refer
- On starting a factory.
- Throughout the life of the factory.
. Contd Industrial Establishment Act
14.0 THE INDUSTRIAL ESTABLISHMENT ACT

14.1 Objectives
- To regulate the conditions of recruitment, discharge,
disciplinary action,
holidays, etc. of workers employed in industrial undertakings
and
establishments.
- Applicable to industrial establishments wherein 50 or more
workmen are or have been employed in the preceding 12
months.
- Central and state governments can make this Act applicable to
establishments employing less than 50 persons, as in the case
of UP and West Bengal.
- In Assam it is applicable to concerns employing 18 or more
109
SMB PROJECTS
workers.
- Submission of draft standing orders.
- Certifications of standing orders.
- Modification of standing orders.
- Registration of standing orders.
- Amendments of the Act.
- Penalties.
- Obligations and rights of employers.
- Obligations and rights of employees.
When to consult and refer
- At the time of expansion of the concern, when the number of
workmen may increase, coming within the provision of the Act.
- When revising standing orders.
. Contd Min Wages Act
15.0 THE MINIMUM WAGES ACT

To determine the minimum wages in industry and trade where
labour organizations are non-existent or ineffective.
- Applicable to all employees engaged to do any work, skilled,

unskilled manual or clerical, in a scheduled employment,
including out-workers.
110
SMB PROJECTS
- Fixation of minimum wages.

- Fixation of minimum wage of employees.
- Procedure for fixing and revising minimum wages.
- Obligation of employees.
- Rights of workers.
When to consult and refer
- At the time of fixation of salary of new/existing employees.
______________________ Project Report Ends
_____________________
111

Manufacturing of PVC Coated Cables

Uploaded by

Copyright:

Available Formats

You might also like

Manufacturing of PVC Coated Cables

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manufacturing of PVC Coated Cables

Uploaded by

Copyright:

Available Formats

SMB PROJECTS

Know-how - A Gateway to Prosperity

Ex. Sr. Manager HPCL ( Project Planning)

Phone / Fax : 91-7263 259052

BASIS & ASSUMPTIONS

PRODUCTION & TECHNICAL

CASH FLOW & FINANCIAL ANALYSIS

List of major Competitors

Suppliers of Plants & Machineires

11 to 15 How to set up an Enterprise

& other relevant chapter

the finished products can be dispatched through Rail and Road

strands. Tinning was used to help removal of rubber insulation. Tight

Modern HV cables have a simple design consisting of few parts. A

LT XLPE multi core cables, ( 1.1 to 11KV ), sizes 161000 mm2

PVC/XLPE Control Cables (110V 1.1 KV) multi core upto 6 mm 2

FRLS / HR PVC Copper Cables

PTFE insulated wires and cables ( -65 deg C 260 deg C )

PVC Copper Flexible wires

1.4.3 Illustrative Photographs :

Wires & Cables in a Bundle

. Market Potential Continues

2.0 MARKET POTENTIAL

development of hydro projects, environmental imperatives driving

transmission super highways throughout the length and breadth of the

as well as beyond the national boundaries and also upgrading

2.3 A Survey of Trends, Innovations and Opportunities

Manufacturers Association (which surveyed the opinions of

2.3.1 Market Trends :

Delivering electricity where and when it is needed poses a

2.3.4 Better cables mean better reliability

2.3.6 Government reform is changing the electricity

A key global trend in the wire and cable industry, also

2.5 Innovative Wire & Cable Solutions for India

power cable compounds should conform to the

polyethylene (XLPE) insulation

provides consistent products that help maximise value and

environmental and physical protection

. Quality Standards continues

Steel Wire Armoured (SWA) Cable

Conductor: consists of plain stranded copper (cables are

Insulation: Cross-linked polyethylene (XLPE) is used in a number

Bedding: Polyvinyl chloride (PVC) bedding is used to provide a

Armour: Steel wire armour provides mechanical protection,

Sheath: a black PVC sheath holds all components of the cable

The PVC version of SWA Cable, described above, meets the

development of extruders for plastics extrusion and cross-linking has

resulted in cable-making installations[9] for making defect-free and

1.5 - 300 Sq. mm.

Upto 61 Core - 300 Sq. mm

Upto Multi Core - 24c X 120 Sq. mm.

CONF. ITD : 113

Flexible and Armoured

Coaxial Cables RG & UR Series

Red, Black, Yellow or Blue.

Red and Black

Red, Blue and Blue.

Red, Yellow, Blue, Grey and Black.