COMPANY PROFILE

SYSKA MITERR PRIVATE LIMITED

Syska Miterr Private Limited is an Indian Non-Government Company. It's a private company
and is classified as 'company limited by shares'.

Company's authorized capital stands at Rs 40.0 lakhs and has 100.0% paid-up capital which is
Rs 40.0 lakhs.

Syska Miterr Private Limited is majorly in Business Services business and currently, company
operations are active.

Company is registered in Chandigarh (Punjab) Registrar Office. Syska Miterr Private Limited
registered address is H NO. 9 CANTONMENTTHE MALL AMRITSAR Amritsar Punjab-143001.

Syska Miterr Private Limited Details

CIN U74999PB2017PTC046642
Status ACTIVE
Company Category Company Limited by Shares
Company Sub-category Indian Non-Government Company
Company Class Private
Business Activity Business Services
Authorized Capital 40.0 lakhs
Paid-up Capital 40.0 lakhs
Paid-up Capital % 100.0
Registrar Office City Chandigarh
Registered State Punjab
Registration Date 23 Jun, 2017

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COPPER WIRE MANUFACTURING PLANT OVERVIEW

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 3 STEP MANUFACTURING PROCESS

In the first phase of the manufacturing process, copper wire is drawn to the proper size in a two-step
drawing process, and then it is annealed and coated with polyethylene insulation. It is tested before
passing on to the next manufacturing phase

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In the second manufacturing phase, insulated copper wire is first twisted into wire pairs, and then the
twisted wire pairs are combined by a strander.

Step-3
Jacketing the cable

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FLOW GRAPH FOR MANUFACTURING OF COPPER WIRE

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DIFFERENT TYPE OF WIRE MANUFACTURING

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 DESCRIPTION OF THE WORK

CRITERIA FOR THE SELECTION OF POWER CABLES

The electrical current in a conductor causes a voltage drop and power losses. The
temperature rise in the cable caused by the losses must be kept within certain limits in order
not to shorten the service life of the cable. The temperature limit varies with the type of
cable, or more precisely the type of insulation. The best way to keep the temperature within
limits specified for the type of cable, is to choose the conductor cross-section so that the
cable and its surroundings with the actual continuous load, achieve thermal balance at a
temperature below or equal to the temperature limit recommended. Cable type and size
should be selected keeping in view the following: -

(1) Application.
(2) Working voltage; earthed or unearthed neutral system.
(3) Load current, load factor, starting duty and frequency.
(4) Installation method.
(5) The environment in which the cable has to operate.
(6) Short circuit current and system protection.
(7) Acceptable voltage drops
(8) Economies.

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How the above factors influence on the choice of cable?

1. Application: The application of the cable determines the basic factors for the choice of

cable type and the rules according to which it must be manufactured. Following are the

major factors for choice of cable type.

2. Conductor materials

No doubt copper is better conductor material owing to its high electrical conductivity and
other electrical/mechanical properties but due to its high cost and scarcity, researches are
being carried out to find other cheaper and abundant metals which may be a close substitute
to copper in electrical application. Aluminum conductors are being used in place of copper
conductors for the past many years and have proved to be quite satisfactory. The lower
conductivity of an Aluminum (61 % of the annealed copper) results in increased dimensions
of the cable and ultimately of conduits and fittings for the same current carrying capacity as
that of a copper conductor cable. Aluminum conductor cables although bigger and
somewhat stiffer when lower number of wires is used for the conductor than the equivalent
copper conductor cables, are still flexible enough to be installed where a copper conductor
cable was formerly used. The advantages of the lighter weight offset the disadvantages of
larger sizes for a given capacity. The use of Aluminum conductor cables should be preferred
as far as possible. The use of flexible copper conductor is recommended where very high
degree of flexibility is required as in the case of mines etc.

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3.Insulating materials:

The right type of insulation material for a particular use depends upon the voltage grade,

operating temperature required, degree of flexibility, current capacity requirement and

restrictions on size etc. and other climatic conditions.

4. Metallic Sheathing:

Either pure lead or different lead alloys are used for Sheathing of PILC cables and each has

its own advantages. The most common and popular alloy is lead Alloy 'E'.

5.Bedding and Serving materials: In case of PVC cables the normal bedding and serving

materials are PVC compound. The normal bedding and serving in case of PILC cables

consist of a combination of an impregnated paper, cotton and Hessian tapes and bituminous

compound. These materials provide protection against corrosion of armor and lead and are

suitable in great majority of installations. However, in special cases where severe chemical

corrosion is to be encountered, the use of PVC bedding and PVC serving is recommended.

6.Armoring:

The purpose of armor is to provide mechanical protection to the cable and to facilitate

earthling for safety requirements. This also carries phase to ground fault currents of the

system safely. Double steel tape provides good mechanical protection but when in addition

longitudinal stresses are encountered during the installation or in service, steel wire/strip

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armoring is recommended for vertical armoring should be preferred. Double wire runs, river

crossing, cables laid on bridges and mine shafts etc. where longitudinal stresses are

expected.

2. The system voltage determines the voltage class of the cables.

3. The current rating is, in general, the decisive factors for fixing conductor cross-section.

But in certain applications where intermittent load is required, it is more relevant to use the

squared average r.m.s. current with a reduced cross section.

4. The power cables must be capable of carrying, the required normal full load current

continuously under the site conditions throughout the year. Therefore, the current ratings

specified must be corrected to site conditions by applying suitable derating/uprating factors

depending upon -

1. Ground or ambient air temperature (max.).

2. Thermal resistivity of soil during dry season.
3. Depth of laying.
4. Total number of cables/circuits in groups.

5. (A) Chemical substances in the environment might cause special stringent requirements

on the outer covering.

(B) If it is necessary to reduce the propagation of fire along cable route combined with

low corrosivity, toxicity and smoke generation characteristics for cables, "FRLS' cables

(Flame Retardant low Smoke) with thermoplastic or thermosetting material or fire survival

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cables with elastomeric material should be used. These types of cables are designed with

special composition of protective sheath materials, and by using beat barrier tapes etc. for

use in such critical fire risk installations.

(C) Short circuit current together with duration of short circuit determines the short

circuit energy the cable insulation has to with stand thermally certain cases a larger size of

cable then the cable required for normal full load current may be needed to match system

short circuit current levels. Voltage drop is also a major factor in deciding the conductor

size of the cable. The cross section of the cable should be chosen such that voltage drop of

the cable for the given route length does not exceed the statutory requirement.

(D) Naturally, the most economical construction and the size of the cable consistent with

required current carrying capacity and laying condition must be selected. Thus, the

selection of particular type of cable i.e. PVC, XLPE, PILC or rubber and the particular

material for screening, sheathing, bedding, armoring or serving etc. out of many choices

available depends upon the usages, laying and climatic conditions. The design of the cable

for a application must be optimized taking into account all the above-mentioned factors. In

case expert guidance in this respect is desired, please contact UCI Technical Service

Division. UCL SATNA

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 Manufacturing Process

The overall stages of manufacturing consist of the following different types of processes.

1) Wire Drawing -Annealing, Tinning, Bunching, Stranding

2) Insulation -Paper/PVC/Rubber/XLPE/Fluoroplastic/Polyethylene

3) Laying

4) Impregnation

5) Lead Sheathing

6) Bedding – Extruded/wrapped/fibrous lapping

7) Armoring -Round wire/Flat strip/Steel tape

8) Sheathing

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The details of above manufacturing processes are as given here under: -

Wire Drawing:

Wires of different sizes are drawn from Aluminum/Copper rods on wire-drawing machines.

The size(diameter) of wire depends upon the over-all cross-sectional area of the ultimate

cable under manufacture as well as the flexibility requirement. Annealed copper Wires for

flexible rubber cables are then tinned before they are released for next process. The tinning

is done by passing the cleaned cu. wires seated with the flux through molten tin both. The

excess of tin adhering to wire surface is wiped out by means of wipers Stranding - The Al or

Cu. wires or tinned copper wires as the case may be are bunched/stranded together. The

direction of stranding of alternate layers is always kept in opposite direction in order to have

tight and balanced configuration of wires. The standard Conductor may be compact circular

or shaped as per the cable construction.

INSULATION

(1) PVC - Different type of PVC compounds are used for required Physical & electrical

properties and continuous operating temperature of cables. PVC compound extruded over

conductor by extrusion process on different sizes of extruders as per the size of conductor.

In line to extrusion process H.V. testing (Spark testing) is being done to check the quality of

extruded core.

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2. Rubber - Natural or synthetic rubber-based compounds are prepared to meet the

physical & Elec. properties and continues operating temp. of cable. Various types of rubber

compounds are then extruded over the conductor as per the requirement of the customer.

3. Paper insulation - In this case insulated paper tapes are lapped on conductor. The

thickness of insulation is built up by required number of paper tapes according to voltage

grade of cables. The top layer of paper tapes is suitably numbered for core identification.

XLPE – Pep cables have become very much popular now a day. These cables are

replacing paper-insulated cables right from low voltage grade to extra high voltage grade. In

these cables two types of constructions are used ie screened and unscreened. 11 KV and

above grade cables are all screened. Conductor screen, insulation and insulation screen

are generally applied in one operation called dual-tandem process. M/s Universal Cables

Ltd is one of the pioneer cable manufacturers of XLPE cable up to 132 KV grade cables in

INDIA.

Vulcanization/Cross-linking: Rubber and XLPE cables are vulcanized after extrusion. This

process is done just after extrusion on CV/CCV/PLCV lines. This process is done to

improve the electrical and physic-mechanical properties of rubber and polyethylene

compounds. In some cases, batch vulcanization is carried out for rubber cables and low

voltage XLPE cables.

Laying up of cables.

The insulated cores are laid up along with filling material and twisted to get approximate

circular Cable. A binding tape is also provided to hold the fillers and maintain the circularity

of laid up cables. In case of paper-insulated cables if the cables are belted type, belt

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insulation is done along with laying up process by providing required no. of paper tapes and

in screened type cables copper woven fabric tape is provided over laid up cores.

Impregnation process:

Paper insulated cables need a special process known as impregnation. The function of this

process is to extract moisture out of paper insulation and impregnate the insulation with

moisture resistant insulating compound. Heating the Cable under vacuum for some period

and then filling the insulating compound over cable within the impregnating vessel do this

process. The cycle of drying flooding and cooling etc. depends on size and voltage grade of

cables. By impregnation the electrical properties of paper insulation are enhanced.

Procedure adopted for drying and impregnation of paper-insulated cables comprises the

following stages.

1. Rewinding the cables in impregnation trays

2. Loading the trays in the impregnation tanks

3. Heating the cables under vacuum

4. Impregnating of cables with impregnation compound for

required period

5. Unloading the cable-trays from the tanks after impregnation.

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The compound used for impregnation is a petroleum product and has excellent electrical

and mechanical properties.

Lead sheathing

After impregnation, lead sheath is applied over the paper-insulated cables. This process is

done by sleeve extrusion (pipe extrusion). The object of Lead sheathing is to prevent the

entry of moisture in the impregnated cable while maintaining the flexibility of cable.

Inner Sheathing/Bedding

PVC and Rubber insulated cables are provided with inner sheathing over laid up cores as

bedding for armoring. In case on PVC cables inner sheathing may be done by lapping

PVC/PE tapes or by PVC extrusion but in case of rubber insulated cables rubber extrusion

is done for this purpose.

Armoring

The armoring is provided to provide mechanical protection of cables during handling

installation. HI is done by providing galv. round steel wires or galvanized steel strips or

double steel tapes over the bedded cables. Though the main function of armoring is to

protect the cable from outside mechanical damages to the cable, but it also serves the

purpose of carrying the short circuit current produced during system failure or any type of

short circuit in the system.

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Sheathing/Serving: -

After armoring or in case of un-armored cables, the laid and bedded cables are provided

with a protective sheathing of extruded PVC or PE sheath. Paper insulated cables are

generally provided with a fibrous lapped serving but PVC or any other type of extruded

sheath can also be given if required.

Telecommunication Cables: Apart from power and control cables, telephone cables are

also manufactured. These cables are generally called PIJF cables meaning Polyethylene

Insulated Jelly Filled cables. In these cables copper wire of suitable size is insulated with

Polyethylene. Two insulated wires are twisted together to form a pair. Required numbers of

such pairs are grouped together and filled with special moisture resistant jelly. The filled

cable is than screened with polythene laminated aluminum foil and sheathed with LDPE

compound. The cable is finally armored with galvanized double steel tapes and jacketed

with LDPE compound.

Final testing: -

All cables are rewound in proper size wooden/steel reels and sent to testing section where

all the cables are subjected to rigorous electrical and physical tests. Both the ends of cables

after testing are sealed and given a unique identification number. These are then handed

over to marketing department for onward dispatch to relevant customer

Quality control

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In syska cables quality is maintained by following a in built quality system which is based on

international specification IS/ISO 9001.

A property organized system of control of quality of product and process is followed for the

efficient production of product acceptable in all respects to the customer. Products are

tested and processes are controlled at all stages of manufactures from raw material to the

finished stage. In addition, certain standards procedures are adopted in order to ensure that

product successfully fulfils the customer requirement.

Electrical and Mechanical maintenance:

Electrical and mechanical departments are responsible for the periodic maintenance of all

machines and equipment’s. A comprehensive schedule of PPM is followed to avoid

breakdowns and thereby loss of machine and men hours. Both these departments are also

looking after breaking down maintenance and installation &commissioning of new machines

and instruments. These departments also carry out calibration of various electrical and

mechanical instruments.

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IMAGES OF REAL TIME MACHINE USED FOR MANUFACTURING
1.RBD MACHINE(Rod Breakdown machine)

Color: Optional Machine Name: RBD/ Big Drawing Machine

Product Dia: 8mm Output Speed: 800m/min

Output Size: 3/26mm Feature: Efficient, high-quality

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Functional view of RBD

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2.MWD(Multi Wire Drawing)

It converts the 8mm copper wire into 0.07mm copper wire.

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BUNCHER (Wire bunching machine)

Single Wire Diameter

0.12mm-0.52mm
Stranding Section Area
0.30mm2-4.0mm2
Core Wire Single Wire Dia
0.5mm-2.0mm
Core Wire Stranding Outer Dia
1.0mm-4.0mm
Pitch
11.6-100mm(34zones)
Max Rotating Speed
2400rpm(4800twist)

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ELECTRICAL WIRE PVC INSULATION PRODUCTION MACHINE

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COILER(For coiling the final insulated copper wire)

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 SPARK TESTER

Voltage Range 0.5 / 15 KV

Test Frequency 2.5 TO 3.5 KHZ

Wave Form Sine Wave A.C.RMS

Wire Size 0.5 to 15mm O.D. (30mm on Demand)

Electrode Bead Chain housing of 70mm long

Max Wire Speed 2500 mts / min (MPM)

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COILING AND PACKGING SECTION

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FINAL PRODUCT READY FOR DISPATCH

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 CONCLUSION

Hence in the last I can say that taking training in such an organization proved to be very

beneficial for me. I learnt quite a lot about processes of cable making, selecting of cable

material, and how different processes like bedding, armoring, serving are done. In short i got

firsthand knowledge of how cables are made.

The first phase of training has proved to be quite fruitful. It provides an opportunity to

encounter with such huge machines.

The architecture of company has various units. They are linked and working of whole plant

is controlled make the student realized that engineering is not just learning the structure

description and working of various machines. But the greater part is planning proper and

management.

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 REFERENCES

1.Mr.RP Singh (plant head syska mitter pvt ltd.)

2.Internet

3.www.reelex.com

4.www.researchgate.com

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