Aluminium Conductors Aac, Aaac, Acsr: Released By: The Development Commissioner (SSI), Ministry of SSI, New Delhi
Aluminium Conductors Aac, Aaac, Acsr: Released By: The Development Commissioner (SSI), Ministry of SSI, New Delhi
Aluminium Conductors Aac, Aaac, Acsr: Released By: The Development Commissioner (SSI), Ministry of SSI, New Delhi
Aluminium Conductors
AAC, AAAC, ACSR
INTRODUCTION
Aluminium Conductors (i) All Aluminium Conducts (AAC) (ii) All Alloy Aluminium
Conductors (AAAC), and (iii) Aluminium Conductors Steel Reinforced (ACSR) are used
in Transmission and Distribution system to carry the generated electrical energy from
generating station to end user.
The Electrical energy is normally generated at the power stations far away from the urban
areas where the consumers are located. There is a large network of conductors between
the generating stations and the consumer.
The network is called the Transmission and Distribution system. The Transmission
system is to deliver bulk power from power stations to the load centres and large
industrial consumers beyond the economical service range of the regular primary
distribution lines where as distribution system is to deliver power from power sector or
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Released By: The Development Commissioner (SSI), Ministry of SSI, New Delhi
substations to the various consumers. This transmission and distribution system can
employ either overhead system or underground system. Transmission of power, overhead
system mainly due to low cost and some other advantages ACSR generally used or
transmission line and AAC and AAAC conductors for distribution of power carry out
mostly the high voltage transmission. For transmission and distribution of electric power
the conductor material used must have the following characteristics:
iii) Low specific gravity in order to give low weight per unit
volume
Copper, Aluminium, Steel and Steel cored aluminium, galvanised steel conductors are
generally employed for this purpose and preferably stranded in order to increase the
flexibility (Solid wires, except of smaller sizes, are difficult to handle and when
employed for long spans tend to crystallize at the points of support because of the
swinging in winds. Stranded conductors usually have a central wire around which there
are successive layers of 6, 12, 18, 24 wires. For 19 layers, the total number of individual
wire is 3n (n+1). If the diameter of each strand is torn diameter of the stranded
conductors will be (2n+1) d. In the process of manufacture adjacent layers are spiraled in
opposite direction, so that the layers are bound together. This method of construction is
called as Concentric Lay, out of above mentioned conducting materials, Aluminium is
widely used due to its cheapness and many others comparative advantages over other
conducting materials. However, owing to the fact that the line or co-efficient of
expansion of aluminium is 104 times that of copper, the sag is greater in aluminium wire,
therefore, steel cored Aluminium (ACSR) wire is used to compensate this property of
Aluminium. The steel conductors used are galvanised in order to prevent rusting and
electrolytic corrosion.
The AAC/AAAC/ACSR conductors for high voltage transmission have first replaced the
bore copper conductors where copper is scarce and costly on the other hand EC grade
Aluminium is easily available in India and as far as the electric properties are concerned,
aluminium is equally good being lighter in weight and for same sage span length of the
transmission could be increased in comparison to copper.
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Released By: The Development Commissioner (SSI), Ministry of SSI, New Delhi
Market Potential
India is a developing country with a fast growing population. The economic growth of
the country and the demand for any essential items grows as a function of population.
Electrical power
demand also grows as a function of population. In today's modern world the dependence
on electricity is so much that it has become a part of our life. The ever increasing use of
electric power for domestic commercial and industrial purposes necessitates to provide
bulk electric power economically. Our present generation capacity is about 1,05,000 MW
but projected demand by 2012 is 205000 MW that means an extra 1,00,000 MW has to
be produced to meet the demand. The electrical energy is normally generated at the
power stations far away from the urban areas where consumers are located. In order to
evacuate this generated power at the door steps at end user, there is a large net work of
Transmission and Distribution system including the Aluminium Conductors. ACSR
conductors are generally used for transmission line and AAC and AAAC conductor for
Distribution purpose. Due to massive rural electrification programme and the
commitment of the Central and State Government to electrify each and every house in a
remote village and also the reforms and efforts and to ensure electricity to all section of
the society on demand, brighten the demand and scope of the conductors.
i) The basis for calculation of production capacity has been taken on single shift basis on
75% efficiency.
ii) The maximum capacity utilization on single shift basis for 300 days a year. During
first year and second year of operations the capacity utilization is 60% and
80% respectively. The unit is expected to achieve full capacity utilization from the third
year onwards.
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Released By: The Development Commissioner (SSI), Ministry of SSI, New Delhi
iii) The salaries and wages, cost of raw materials, utilities, rents, etc. are based on the
prevailing rates in and around Cuttack. These cost factors are likely to vary with time and
location.
iv) Interest on term loan and working capital loan has been taken at the rate of 16% on an
average. This rate may vary depending upon the policy of the financial
institutions/agencies from time to time.
v) The cost of machinery and equipments refer to a particular make / model and prices
are approximate.
vii) The project preparation cost etc. whenever required could be considered under pre-
operative expenses.
viii) The essential production machinery and test equipment required for the project have
been indicated. The unit may also utilize common test facilities available at Electronics
Test and Development Centres (ETDCs) and Electronic Regional Test Laboratories
(ERTLs) and Regional Testing Centres (RTCs).
Implementation Schedule
The major activities in the implementation of the project has been listed and the average
time for implementation of the project is estimated at 12 months:
1. Preparation of 1
project report
2. Registration and 1
other formalities
3. Sanction of loan by 3
financial institutions
a) Placement of orders 1
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Released By: The Development Commissioner (SSI), Ministry of SSI, New Delhi
b) Procurement 2
c) Power connection/ 2
Electrification
d) Installation/Erection 2
of machinery/Test
Equipment
5. Procurement of 2
raw materials
6. Recruitment of 2
7. Trial production 11
8. Commercial production 12
Notes
Technical Aspects
Process of Manufacture
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Released By: The Development Commissioner (SSI), Ministry of SSI, New Delhi
Purity of aluminium for the items to be used in electrical and electronic industries shall
be 99.9%. The quality of the Aluminium conductors produced can be controlled by sticky
following the related IS specifications right from beginning of raw material:
1. Ensuring the correct quality of raw material as per IS 5484:1978 EC grade aluminium
rods produced by continuous casting and rolling. The aluminium content shall not be less
than 99.5% and copper conductors shall not be more than 0.04 per cent.
The test to be carried out as per above mentioned IS Specification are enumerated in
process flow chart of aluminium conductor manufacturing. Obtaining ISO certification
can further boost the credibility of the unit.
Quantity : 468 MT
Pollution Control
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Released By: The Development Commissioner (SSI), Ministry of SSI, New Delhi
India having acceded to the Montreal Protocol in September 1992, the production and use
of Ozone Depleting Substances (ODS) like Chlorofluore Carbon (CFCs), Carbon
Tetrachloride, Halons and methyl Chloroform etc, need to be phased out immediately
with alternative chemicals/solvents. A notification for detailed Rules to regulate ODS
phase out under the Environment Protection Act, 1986 have been put in place with effect
from 19th July 2000.
Energy Conservation
With the growing energy needs and shortage coupled with rising energy cost, a greater
thrust in energy efficiency in industrial sector has been given by the Government of India
since 1980s. The Energy Conservation Act, 2001 has been enacted on 18th August 2001,
which provides for efficient use of energy, its conservation and capacity building of
Bureau of Energy Efficiency created under the Act.
iii) Optimum use of electrical energy for heating during soldering process can be
obtained by using efficient temperature controlled soldering and de-soldering stations.
v) Use of power factor correction capacitors. Proper selection and layout of lighting
system; timely switching on-off of the lights; use of compact fluorescent lamps wherever
possible etc.
Financial Aspects
A. Fixed Capital
Built up area:
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Released By: The Development Commissioner (SSI), Ministry of SSI, New Delhi
Total 10,80,000
machine 3 dies
with spooling
machine 11 Dies
Tubular
Stranding
Machine
multilayer
stranding
machine
(61 strands)
treatment furnace
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Released By: The Development Commissioner (SSI), Ministry of SSI, New Delhi
machine
IMT Cap.
IMT/Chore
Total 54,19,000
Testing Equipments
Machine
Micrometer etc.
equipment
equipment
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Released By: The Development Commissioner (SSI), Ministry of SSI, New Delhi
facilities/equipment
and equipment
Total 64,48,900
and equipment
Other fixtures
Total 65,08,900
(i) Personnel
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Released By: The Development Commissioner (SSI), Ministry of SSI, New Delhi
executive
Engineer
workers/Helpers
Total 34,900
Total 40,135
Rod EC Grade
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Released By: The Development Commissioner (SSI), Ministry of SSI, New Delhi
Steel Wire
Total 33,05,750
Total 78,211
Insurance 2,000
Total 18,000
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Released By: The Development Commissioner (SSI), Ministry of SSI, New Delhi
Financial Analysis
Total 4,32,37,200
(Rs.) (Rs.)
Conductor
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Released By: The Development Commissioner (SSI), Ministry of SSI, New Delhi
(Rs.)/MT (Rs.)
The turnover has been calculated on the basis of weight taking average wire for different
size of cable as per IS specification. Alternating the sale price can also be considered as
per Km. of different size conductors.
= Rs. 62,70,300
4,95,07,500
= 12.67%
= 62,70,300 × 100
1,80,00,000
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Released By: The Development Commissioner (SSI), Ministry of SSI, New Delhi
= 34.84%
Total 38,47,248
B.E.P.
= FC × 100
FC + Net profit
= 38,47,248 × 100
38,47,248 + 62,70,300
= 38,47,24,800
1,01,17,548
= 38.45%
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Released By: The Development Commissioner (SSI), Ministry of SSI, New Delhi
Additional Information
b. The Electrical Technology is undergoing rapid strides of change and there is need for
regular monitoring of the national and international technology scenario. The unit may,
therefore, keep abreast with the new technologies in order to keep them in pace with the
developments for global competition.
c. Quality today is not only confined to the product or service alone. It also extends to the
process and environment in which they are generated. The ISO 9000 defines standards
for Quality Management Systems and ISO 14001 defines standards for Environmental
Management System for acceptability at international level. The unit may therefore adopt
these standards for global competition.
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Released By: The Development Commissioner (SSI), Ministry of SSI, New Delhi
Ahmedabad_382440
12. M/s. Hindustan Wire Netting Co. Pvt. Ltd. 55-57, Nagadevi Cross,
Mumbai.
14. M/s. Nehru Engineering and Sons Liluah, 11/11, Kundan Lane, 9611,
Howrah-711209
15. M/s. Super Cable Machines India Pvt. Ltd. Super Nagar, Mangli areas,
Ajmer-305203,
Testing Machin
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Released By: The Development Commissioner (SSI), Ministry of SSI, New Delhi
Delhi-110 093.
18. M/s. Hargolal and Sons, Ambala Cantt, Haryana, 133 001.
Welding Machine
Rajasthan.
Ahmedabad-360 023.
Howrah
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Released By: The Development Commissioner (SSI), Ministry of SSI, New Delhi
Furnance
1. M/s. NALCO
Steel Metal
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