VOLUME I | ISSUE II | APRIL 2010
Rs. 125
WIRE BULLETIN India’s Quarterly Bulletin Dedicated to the Wire and Cable Industry
India companies among those at wire 2010
ASK THE EXPERT Q: How can the diameter of a closing
die in front of a double twist buncher be determined? With bunched wire constructions that have an odd number of wire ends, how is the finished diameter determined? Once the theoretical diameter is established, how much larger is the die opening? E.g., Annealed copper wire - .080" diameter x 4 ends or aluminum wire - .072" diameter x 5 ends.
Expectations that more than 40,000 visitors from around the globe will come to wire 2010 at Düsseldorf to establish new international contacts, conduct business, and get inspiring impulses is enough reason to cheer. That goes especially for the 45 Indian companies (see p. 3 for list) that will exhibit to make their presence felt in the strongest way possible. That count is still quite low compared to the
See answer on p. 11
NEWS BITES • Union Finance Minister Pranab Mukherjee, projects economic growth in 2010 to exceed Central Statistical Organisation (CSO) 7.2% projection. • In a bid to boost the lagging rural consumption of steel, the Ministry of Steel has instructed state-owned companies to open sale depots in rural areas. • India to release a national manufacturing policy in June to attract more local and foreign investment.
QUOTABLE QUOTES may never know what results come “of You your action, but if you do nothing there will be no result.” ~ Mahatma Gandhi
“A little knowledge that acts is worth infinitely more than much knowledge that is idle.” ~ Kahlil Gibran
“
I have been impressed with the urgency of doing. Knowing is not enough; we must apply. Being willing is not enough; we must do.” ~ Leonardo da Vinci
View of activity at the booth of Swissbased Maillefer SA at wire 2008. overall count of exhibitors, who fill seven halls at the massive Fairgrounds complex in Germany, but it has slowly increased from past stagings of the biennial trade show as more India-based manufacturers and suppliers realize that this is an event that they can ill-afford to miss. This year’s show is especially important as the wire and cable companies in most countries are now gathering momentum again after the bleak period of global economic downturn. For Indian participants, what with the country’s GDP slated to grow at 7.2 per cent and the government’s emphasis on developing infrastructure in the coming years, this show is an opportunity to set up business contacts and also learn about new technologies in the offing. “It is undoubtedly the biggest show of its kind in this sector and there are so many direct and indirect benefits that we have obtained from our participation over the years,” said Ashish Tyagi, Director, Assomac Machines. That opinion is echoed by Indian participants at the show,
which as of March 5 had more than 1,130 exhibitors, 815 of whom are from outside Germany. “It’s a truly global event where we can meet thousands of people from these sectors and expand our reach to cover more countries as also introduce advanced processes into our production systems,” said Chandraprakash Bhansali, Director, Bhansali Steel. J.S. Gupta, Director, Ajex Turner, agreed that the results have been worthwhile. “We have been a part of wire 2010 [for] more than a decade and this event has contributed a lot to the growth of our company. For instance, we have representation in five countries outside India due to the contacts established here and we have also acquired dealerships for foreign countries in India.” From an Indian perspective, wire 2010 will be a fresh learning experience. “There is greater need now than ever to know what’s going on across the world because of India’s emerging global status and that’s what makes our presence here so very necessary,” Tyagi said.
WIRE BULLETIN will be on display at the Wire Association International booth (Hall 11 B-25) at wire Düsseldorf. Among the companies represented at the event will be WAI Wire and Cable Services Pvt. Ltd. introducing its WIRE BULLETIN, which will be on display at the Wire Association International booth, Hall 11 B-25. continued on p. 3
Prysmian acquires majority stake in Ravin Cables
IN THIS ISSUE: Editorial .............................. 2 World Calendar ................... 3 Industry News ..................... 4 People ................................ 6 Featured Concepts .............. 7 Production Tips ................. 10 Products, Media, & Technology .................... 11 Technical Article ............... 12 Classified & Ad Showcase ......................... 16
The Prysmian Group, a world leader in the energy and telecommunications cables industry, has taken a majority 51 per cent controlling stake in the Indian group of Ravin Cables for an overall investment of around Euro 26 million. Ravin is one of India’s most competitive and reputed cable manufacturers, with a range including low- and medium-voltage cables and a market that extends to Africa and the Middle East. Apart from its main manufacturing facility in Pune, Ravin is also present in the Emirate of Fujairah with the company Power Plus Cable Co. LLC, a joint venture with the Fujairah government, for which it manages operations. Power Plus is equipped to produce high-voltage cables. The group has a total of 355 employees in its two facilities. “We are very pleased to have found a wellreputed, well-managed and competitive partner in India who is also present in the
Middle East with whom we look to pursue a growth strategy with a primary focus on the development in the areas of hightech cables for utilities as well as industrial cables. This operation also allows us to have a manufacturing presence in another strategic market like the Middle East,” said Valerio Battista, Chief Executive, Prysmian. The Indian market for high-voltage cables is expected to double its size in the next three years to meet the country’s dynamic economy and the need for rapid power transmission and distribution grid development.|WB
Fiber optic cable to connect Asia and Europe The Kodiak-Kenai Cable Company (KKCC) announced plans to finance, design, build and operate an express undersea fiber optic cable connecting Asia and Europe. The undersea fiber optic cable will be routed through the Arctic. “This link is expected to be completed in 2013, and will enhance global broadband connectivity by providing enhanced internet capacity, security and latency compared to existing offerings,” stated a press release issued by the company. “ArcticLink is the answer to the fastgrowing telecommunications demands created by the globalised economy. Creating this international broadband expressway through the Arctic will allow unprecedented capacity, unmatched security and reliability, and a dramatic latency reduction. Connecting these three continents directly is truly historic,” said Walt Ebell, CEO of the Alaska-based developer. The project is slated to begin construction in 2011. The 10,000-mile undersea fiber optic ArcticLink utilises a politically stable and secure route running through Japan, the United States, Canada, Greenland, the Arctic region, and the United Kingdom. The project will use four, 40 gigabit-per-second sub-sea fiber pairs, providing four times the existing capacity per wavelength for a combined system capacity of 6.4 terabits per second. It will also have record setting latencies of less than 90 milliseconds, a nearly 50 per cent reduction compared to today’s preferred Asia-Europe route latency times. To develop the ArcticLink, KKCC, which is owned by Alaska Native Corporations, Old Harbor Native Corporation and Ouzinkie Native Corporation, joined with KhaNNET and formed the Arctic Cable Company, LLC (ACC). KhaNNET is a member of the Khanjee family of companies, a company that develops infrastructure for all sectors of the energy industry, large project financing, telecommunications, and real estate projects around the world. ACC will lead the international consortium to finance, design, engineer, build, and operate the undersea project.|WB
A D V E R T I S M E N T
APRIL 2010
EDITORIAL
T
he time for celebrations is here. While it is true that the Union Budget 2010 has not made any specific mention about the steel, wire, or cable industries, the indirect benefits are clear. Finance Minister Pranab Mukherjee’s proposals will indirectly boost overall demand for all such products, because they would raise the outlay on urban development and housing by 75 per cent to Rs 5,400 crore and an additional 25 per cent of plan outlay for rural infrastructure. Further, the focus on infrastructure spending, allocation of funds for railways and highways and emphasis on power sector growth will also boost the wire and cable sectors. There’s more good news which will surely boost rapid growth. Karnataka is set to emerge as a major steel making hub as POSCO and ArcelorMittal have received clearances from the government to set up plants there. This will, in turn, help those operating in the wire and associated sectors. Projections are that the amazing growth curves in the telecom and television sectors will not only drive the existing companies to invest in expansion of capacities but also open the doors for new players to step into this space. India’s average GDP growth over the next five years will be 7.2 per cent, driven mainly by the turnaround in the manufacturing sector. And if proof was required of the mood of optimism, note that more than 40 Indian companies will be exhibiting at wire Düsseldorf, including WIRE BULLETIN. See story on page 1.
Huned Contractor Editor
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WIRE BULLETIN Publisher | Steven J. Fetteroll Editor | Huned Contractor Contributing Writer | Mark Marselli Director of Marketing Services | Janice E. Swindells Graphic Artist | Adrienne E. Simpson WIRE BULLETIN is published quarterly by WAI Wire and Cable Services Pvt Ltd, a wholly owned subsidiary of the Wire Association International, (WAI) Inc. ©2010 by WAI Wire and Cable Services Pvt Ltd. All rights reserved worldwide. No part of this document or related files may be reproduced or transmitted in any form by any means (electronic, photocopying or otherwise) without the prior written permission of the publisher. Address all correspondence concerning advertising production, editorial, and circulation to WIRE BULLETIN, E-402, Kumar Pragati, Off NIBM Road, Kondhwa, Pune - 411 048, India, Tel.: 9881084202. Printed in India by K Joshi & Co. The publisher of Wire Bulletin assumes no responsibility for the validity of manufacturers’ claims made herein and cannot attest to the accuracy of the included information. Subscription rates: Rs. 125 per year, India. Single copies: $6 in the U.S.; all other countries $7. Periodicals postage paid at Guilford, CT 06437, USA. WIRE BULLETIN grants photocopy permission to libraries and others registered with Copyright Clearance Center (CCC), 21 Congress St., Salem, MA 01970, USA, for a fee of $0.50 per article. Payments should be sent directly to the CCC. Requests for bulk orders or reprints should be sent to WIRE BULLETIN, E-402, Kumar Pragati, Off NIBM Road, Kondhwa, Pune - 411 048, India, Tel.: 9881084202. POSTMASTER: Send address changes to WAI Wire and Cable Services Pvt Ltd, 501, Rainbow Plaza, S. NO.7, Pimple-Saudagar Vil. Rahatani, Pune - 411017, India.
CALENDAR & FRONT PAGE NEWS wire 2010 continued from p. 1
WORLD CALENDAR April 12-16, 2010: wire Düsseldorf 2010 Düsseldorf, Germany. The world’s largest wire and cable trade show, wire Düsseldorf, will be held April 12-16 at the Messe Fairgrounds. The biennial event, organized by Messe Düsseldorf, featured more than 1,100 wire exhibitors in 2008. Attendance topped 40,700 visitors from 72 countries, with more than half from outside Germany. See story on page 1. Contact: Messe Düsseldorf India Pvt. Ltd. | Commercial Complex, 2nd Floor, Pocket H & J, Sarita Vihar, New Delhi – 110076, India, Tel.: 91 (0)11 2697-1745, -1056, -1066, Fax: +91 (0)11 2697-1746, messeduesseldorf@md-india.com
May 12-13, 2010: Wire Expo 2010 Milwaukee, Wisconsin, USA. To be held at the Midwest Airlines Center, this event includes the WAI’s 80th Annual Convention, trade show, and technical program. Wire Expo will be preceded by the AWPA’s Long Products Supply Chain Symposium and co-located with The National Electrical Wire Processing Technology Expo. Contact: WAI | Tel.: (001) 203-453-2777, www.wirenet.org
September 2010: wire China 2010 Shanghai, China. Contact: Messe Düsseldorf | Tel.: 86-23-6232 8000, www.wirechina.net
September 13-16, 2010: Minerals Metals Metallurgy Materials New Delhi, India. To be hosted by Tafcon, Minerals Metals Metallurgy Materials is a specialised show for metallurgical technology products and the services sector. It will showcase technology from processing prime and raw materials to shaping of steel and nonferrous metals as well as technology for environmental control, engineering, testing, and more. Contact: Tafcon | C-60, Nizamuddin East, New Delhi, Tel.: 011-24352141
November 7-10, 2010: 59th IWCS Conference™ Providence, Rhode Island, USA. Contact: IWCS | Tel.: (001) 732-389-0990, phudak@iwcs.org, www.iwcs.org
November 18-20, 2010: Wire & Cable India 2010
Some of the Indian companies set to exhibit at wire Düsseldorf 2010 are listed below. A1 Fence Products Stall No: 16D52 Products: Weld-mesh; razor wire; gabions. Email: saurabh@a1fenceproducts.com Ajex Turner Stall No: 11F02 Products: Wire dies; die repair machines. Email: sales@ajexturner.com Aksh Technologies Stall No: 9E55 Products: Waterswellable yarns. Email: chetan@akshoptifibre.com Alok Ingots Stall No: 17A66 Products: Billets; bars; and wire rods. Email: chirag@bochmail.com Anand Arc Stall No: 16E05 Products: Stainless steel/aluminium wires. Email: anand@anandarc.com Anu Extrusion Stall No: 15D33 Products: Cold heading and drawing dies. Email: amitmaheshwari@anugroup.net Assomac Machines Stall No: 17C07 Products: Wire and cable machines; steel. Email: ashishtyagi@assomac.in Bedmutha Wires Stall No: 16B53 Products: Steel; various MS wire types. Email: bedmuthwires@rediffmail.com Bhansali Steel Stall No: 17C24 Products: Bars; flanges; and wire rods. Email: wir@bhansalistainless.com Cable Tech Machines Stall No: 16C45 Products: Stranding/armouring machines. Email: info@cabletechindia.com
Chhaperia Mica Products Stall No: 16C43 Products: Mica paper; tape; and sheet. Email: sales@micagroup.net D H Exports Stall No: 17B20 Products: Stainless steel bright bars. Email: pkanugo@dhexports.com Garg Inox Stall No: 9B70 Products: Stainless steel galvanized wire. Email: aayush@gargwire.com Gujarat Polymers Stall No: 16C51 Products: Polyester film. Email: gpolymers@vsnl.com Hindustan Stainless Stall No: 17D36 Products: Bars; wires; rods; and tubes. Email: vimalb@hindustanstainless.com India Steel Works Stall No: 16G64 Products: Billets; rods; bars; and wires. Email: agupta@indiasteel.in Indore Wire Co. Stall No: 16C53 Products: Rods; yarn; cord; and cable gel. Email: export@indore.co.in ITCO India Stall No: 9E55 Products: Filling and specialty gels. Email: chandra@itcoindia.com JLC Electromet Stall No: 16G59 Products: Alloys; welding and dumet wires. Email: sjtaly@jlcelectromet.com Jyoti Steel Stall No: 16F60 Products: Stainless steel; and carbon steel. Email: export@jyotisteel.com Kalpena Industries Stall No: 12D75 Products: PVC and PE compounds. Email: rkkothari@kalpena.co.in
continued on p. 8
Mumbai, India. This event, organized by the Confederation of Indian Industry, will be held at the Bombay Exhibition Centre in Goregaon. Contact: Confederation of Indian Industry | Tel.: 91-22-24931790, www.cii.in/
May 2-5, 2011: Interwire 2011 Atlanta, Georgia, USA. WAI returns to the Georgia World Congress Center for the trade show and the Wire Association’s 81st Annual Convention. Interwire is an international trade event that includes exhibiting companies, speakers, and attendees from more than 50 countries around the world. Interwire is the largest and longestrunning wire and cable marketplace in the Americas where buyers, sellers, and researchers connect with new contacts and colleagues. Details about speaking opportunities and exhibit space purchase are available through The Wire Association International, the event organizer. Contact: WAI | Tel.: (001) 203-453-2777, www.wirenet.org
May 20-22, 2010: Communications India Bengaluru, India. Communications India 2010 will showcase all the capabilities, technologies, and advances related to communications and telecom industries. The expo serves as a platform for companies involved in communications, manufacturing of telecom equipment, cable and optical fiber manufacture, wireless broadband, data network services, Internet services, and satellite communications in India and abroad to display their products and innovations. Contact: Mr. George Johnson | 309, R K Apartments, Block 12, Hoysala Nagar 3rd Main, 6th Cross, R.M. Nagar, Bengaluru, Tel.: 080-65605052
June 19-23, 2011: JI Cable Versailles, France. This international conference on insulated power cables, which has multiple organizers and was last held in 2007, will present a comprehensive forum about power cables as well as exhibits. Contact: J1 Cable 11 | www.jicable.org
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INDUSTRY NEWS KEI signs pact with Brugg Kabel
Cable and wire manufacturer KEI Industries Ltd. announced that its Board of Directors approved a technical collaboration agreement with Switzerland-based Brugg Kabel AG to manufacture extra-high voltage (EHV) cables ranging from 66kV/110kV/132kV to 220kV. The agreement will allow KEI to impart technical know-how from Brugg Kabel, which includes design, manufacturing, testing, training of personnel along with jointing techniques, and complete EHV system design (manufacture, installation, testing, and commissioning) of EHV cables. The collaboration will help the company’s presence in the extra-high voltage cable segment by securing contracts from various public utilities (central/state) and private segments. The New Delhi-based company said the cables would be manufactured at its Bhilwadi and Chopanki facilities in Rajasthan. Production of 220kV cables would commence by September this year. KEI said the demand for extra-high voltage cables up to 400kV would grow exponentially, with the economy showing signs of recovery and the government’s focus on power projects in the Fifth Five Year Plan. The rapid load growth compels transmission/distribution of power through underground cables because of the major problems with right-of-way issues especially in large cities. Besides, the connections to bulk power consumers in the industry sectors—such as cement, steel,
refineries, petrochemicals, and supply of power to special economic zones, multiplexes, large residential complexes—will boost the demand for EHV cables. Presently, restricted capacity exists in 132kV/220kV segments, and India imports 90 per cent of its requirements. The present association with the Swiss firm will definitely reduce the burden on imports, and lower the project costs, the company said. Brugg Kabel manufacturs high-voltage/ extra-high-voltage cables, along with jointing and cable accessories in cable grades up to 500kV and it specialises in turnkey systems/design of extra-high-voltage cable projects with world over installation.
facilities. Meanwhile, Gupta affirmed that there would be no equity participation in the proposed projects. KEI earns 15 per cent of its revenue from Africa and West Asia. The company is also planning to gain a major chunk in the EHV cable segment in India. It will start production of such cables at its Chopanki plant in Rajasthan by the end of August 2010. EHV cables worth about Rs 400 crore were imported to India in 2008-09. Currently, there is demand for cables worth Rs 700-800 crore in the country, where the industry is growing at a CAGR of 35-40 per cent. “We are aiming at a share of Rs 300 crore in the EHV cables market in initial years,” Gupta said. KEI has already invested Rs 110 crore in its Chopanki plant and an additional Rs 40 crore will be pumped in by 2010.
Tata Steel set to acquire Incab
In another development, KEI Industries plans to set up low- and medium-voltage cable manufacturing plants in Africa and West Asia to tap those growing markets where the company has already been distributing cables, said KEI Chairman and Managing Director Anil Gupta. The Rs 1,085-crore KEI holds around 10 per cent market share in the Rs 15,000-crore Indian cables market. “Africa is a virgin market while there is enough potential in West Asia due to its mounting oil and gas exploration,” Gupta said. He, however, refused to disclose the exact dates for the commissioning of the
With Tata Steel now set to acquire Incab, the cable manufacturer, the decks have been cleared for it to enter into the cable business in a big way. In December 2009, the Board for Industrial and Financial Reconstruction (BIFR) approved the revival plan proposed by Tata Steel over two other bidders. “We have offered a Rs 98.7 crore package for Incab,” a Tata Steel spokesperson said. The BIFR has chosen Tata Steel as it considered the Tatas to be in a better position to take care of Incab’s 1,600 workers. The other two bidders in the fray were RR Cables and Pegasus.
Adhunik to increase steel rod production
Earlier, Tata Steel had decided to move court in the interest of the workers and at the request of the Incab unions. During the proceedings at the Delhi High Court, Incab workers had filed an application pleading that Tata Steel should be directed to submit a revival scheme for the sick firm. Subsequently, Tata Steel was asked by the Delhi High Court to submit its proposal. After several rounds of hearing, the ruling of the BIFR went in favour of Tata Steel. Incab Industries, cable producer of yesteryears, has a plant located on approximately 176 acres of sub-leased land adjacent to Tata Steel in Jamshedpur, a manufacturing facility in Pune, and assets in Kolkata. However, its manufacturing activities have been in a state of suspension for the past 10 years. Prior to the ruling announced by the BIFR, Incab Industries Employees Association’s (IIEA) President Rakeshwar Pandey had led a delegation of 27 office-bearers of the company with the trade unions of Kolkata and Pune to meet Tata Steel’s Managing Director B. Muthuraman, requesting him to take over the company. Tata Steel agreed to take over the company based on a few conditions including acceptance of the sick cable company’s trade unions alongside Pandey’s leadership on the issue, extension of full support to the steel major in the forthcoming process, and that it would not be deemed necessary for Tata Steel to produce cables at the Incab plants. Before shutting down, Incab was engaged in the manufacturing of cables for mining, power, and defence companies. According to an industry observer, Tata Steel’s acquisition of Incab will help the former establish a niche placement in the cable sector which, in India, has grown rap-
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idly. To quote from Swapna Naik’s article on the cable industry in the August 2009 issue of the Indian Electrical and Electronics Manufacturing Association, the cable industry is slated for tremendous growth in the coming years because of its direct relationship with the demand for power in India. “The size of the building wire and cable segment is estimated to be Rs 5,000 crore while that of power cables is about Rs 8,350 crore. There are few manufacturers who currently manufacture cables up to 220 kV grade whereas a larger number of manufacturers manufacture medium voltage cables up to 33kV, besides LV cables,” Naik said. Considering the strong domestic demand for cables in the power sector, overseas cable manufacturing giants have entered into the market through joint ventures with Indian cable manufacturers for manufacturing Extra High Voltage (EHV) cables and special types of cables. The increase has been observed in the demand for Cross Linked Polyethylene (XLPE) cables, whereas the demand for Paper Insulated Lead Sheathed (PILC) cables is almost negligible. In the year 2008-09, the production of Low Voltage Polyvinylchloride (LVPVC) and XLPE cables was about 2,15,000 kms whereas for HV and EHV-PVC and XLPE power cables (3.3 KV and above), the production was about 21,580 kms. “If Tata Steel gets into the cable market through Incab, it will find for itself a ready market,” an industry analyst said.
To enhance its production capacity of steel rods and TMT bars, Kolkata-based Adhunik Corp Ltd., an arm of Adhunik Metaliks Ltd., will use funds from its public offering of shares to finance the second phase of its steel project, according to a media report. “Adhunik Corp is setting up 4,00,000 tonne steel capacity in the first phase for an investment of Rs 850 crore,” said Mahesh Agarwal, Managing Director, Adhunik Corp Ltd. The company has received 505 acres out of 661 acres’ land required for the project from the state government. “In the second phase, we would be creating 5,00,000 tonnes of steel capacity and a 1 million tonne cement plant for which we would come out with an IPO,” he said. A captive power plant of 60 megawatt is also being built and Agarwal said there are plans to create 1,000 MW capacity but did not elaborate further.
Cords Cable announces expansion plans Cords Cable Industries, a manufacturer of LT control cables, LT power cables, instrumentation cables, thermocouple extension cables, compensating cables, coaxial cables, telephone cables, panel wires/household wires, and networking cables has announced a USD 1.9 million expansion plan. According to Naveen Sawhney, Managing Director, Cords Cable Industries, the company has commenced the construction of a new project in the Alwar district in Rajasthan. “We have already placed the machinery orders. This is basically to augment our capacity, particularly of specialty cables. The production of the factory will be going towards the power industry, refineries, airport modernisation, metro railways etc.,” he said. The company expects about 20 to 25 per cent of its products to be sold in the overseas markets across Eastern Europe, the
INDUSTRY NEWS Middle East, and Africa. “The plant will be commissioned by July 2010,” Sawhney said. The company was established in 1987 by a group of industry professionals with an objective of catering to a growing requirement for high quality customised cables. Over the years it has developed a wide range of specialised cables to address the specific requirements of industries involving modern process technologies, instrumentation, and communication with a demand for the highest standards of precision and reliability.
Power cables may provide internet connectivity A key staffer at a research project on Broadband over Power Lines (BPL) being completed at the Delhi Technological University (DTU) believes that the technology being developed may revolutionise information technology at a fraction of a cost. If found practical for easy implementation, a home power cable will now allow access to high-speed Internet connection, video surveillance, e-governance, distance education, real-time TV streaming, and much more. Monitoring and controlling electronics gadgets at home from office will also become a reality. The BPL research was initiated in July 2007. A pilot study conducted at Alipur, a village on the G T Karnal Road in New Delhi, was ‘tested okay.’
At present, broadband connection has a speed of 100 MBPS, but BPL promises 200 MBPS and an easy-to-use connection within 30 minutes. “It is fast as the central point is connected to all the nodes which are directly in line with the central server, unlike the conventional practice of branched network or tertiary network. Here, every user is directly connected to the injection point. This doesn’t need any additional infrastructure. Just one component at the power line and within 30 minutes the whole building or the neighbourhood can be connected,” Vishal Verma, Prinicipal Investigator, DTU, was quoted in the media. Broadband connections can be provided using diverse technologies such as fiber optics, satellite, wireless radio (wi-max/wifi), coaxial cable, and telephone twisted pair (DSL), all of which require extensive investments in order to reach all homes and business establishments. BPL, on the other hand, allows easy installation with relatively low entry costs because it requires no wiring changes to enable broadband connection (it can be accessed from any outlet) and makes use of existing power grids without adding a single new cable.
ISWP rolls out expansion plan The Indian Steel and Wire Products (ISWP) is set to launch a Rs 20 crore expansion programme. The company, which was revived by Tata Steel in 2003, aims to become a leading producer of metal wire in eastern India. At a programme organised to commemorate five years since Tata Steel took over ISWP, Chairman Partho Sengupta said that they would come up with a new Thermomechanical Mill
Treatment (TMT) mill and procure a wiredrawing machine (GF1) from the steel giant’s wire division, based at Borivali in Mumbai. The new TMT mill would cost Rs 6 crore. The company proposes to invest another Rs 14 crore to procure the wiredrawing machine. The original concern was formed some time immediately following World War I along with so many other industrial concerns, which came into existence as a result of war property and the necessity of having key industries established. But the concern did not survive the heavy slump that followed due to foreign competition and it was ultimately brought under liquidation. It was then purchased by Sir Indra Singh in 1927. The total capacity of the mills at the time of purchase was less than 1,500 tonnes of wire and wire products per year. The capacity of the plant was increased to nearly 12,000 tonnes of wire and wire products and government protection was granted in 1931. It took approximately three years i.e., from 1932 to the start of 1935, before the mill could re-establish operations. The capacity of the plant was raised to between 40,000 and 45,000 tonnes of rods per year. The concern had grown sufficiently by then and was made into a limited liability company on April 1, 1935, with the founders as its managing agents. The company closed in 1998 after its losses accumulated to several crores at which point it was then referred to the Board for Industrial and Financial Reconstruction (BIFR). At the time of takeover, the company had incurred losses to the tune of Rs 78 crore. After being closed for six years, ISWP struck a deal with Tata Steel on December 20, 2003. The ISWP manufactures wire rods, cast-iron, and steel-based rolls. According to Sengupta, the company has taken the initiative to ensure skilled labor at the company. Recently, the ISWP established a training centre on its premises where company employees will be trained.
requirement of additional Rs 363 crore. The state-run Industrial Promotion and Investment Corporation of Orissa Limited (IPICOL) and Orissa Mining Corporation (OMC) have 22.23 per cent and 4.6 per cent stake in NINL. A high-level meeting chaired by Chief Minister Naveen Patnaik explored the possibilities of mobilising the resources out of internal accruals of the state-owned OMC and borrowing from financial institutions. The majority opinion at the meeting was to retain the share of the state government in the company and urge the central government to appoint professionals on the board of management. With the merger of Konark Met Coke Ltd. (KMCL) promoted by MMTC and the state government for production of metcoke and power five years ago, NINL had emerged as an integrated complex. Besides, the project has firm iron ore supply linkages and also has captive iron ore mining rights for reserves estimated at 110 million tonnes.
India will become second largest steel maker by 2012 By 2012 India will more than double its capacity of 57 million tonnes as part of the push being given to assist overall infrastructure development, making it the second largest steel producer in the world Steel Minister Virbhadra Singh has said. “I have set a target of 124 million tonnes by 2012. We will become the world’s second largest steel producer. But more importantly, India has a vast capacity to consume that kind of output. It is necessary for our infrastructure development. If I also take greenfield projects into account, we have expression of
interest for projects worth over USD 80 billion,” Singh said in an IANS media agency interview.
At present China is the largest steel maker in the world with a capacity of more than 600 million tonnes, followed by Japan and South Korea. India ranks fourth. A five-term chief minister of Himachal Pradesh, the veteran Congress party leader said the state-run Steel Authority of India (SAIL) alone has targeted to virtually double its capacity to nearly 30 million tonnes. “These expansion projects will sail through. Both at Bokharo and Bhilai, the company has enough land to take up the projects,” Singh said. The minister said that the state-run steel company will also go for a public issue and partial divestment of equity during the early part of next fiscal period and that a decision has already been taken in this regard. The veteran minister said another company under his ministry’s administrative control—National Mineral Development Corp. (NMDC)—will also go for divestment quite soon. He further stated that he was keen that some large projects of global companies also go on stream soon, including the USD 12 billion integrated steel unit of South Korea’s Posco in Orissa and two similar ones of Arcelor-Mittal in Orissa and Chattisgarh.|WB
NINL set to expand with government equity Nilachal Ispat Nigam Limited (NINL), which produces 3 lakh tonnes of wire rod each year along with 4.92 lakh tonnes pig iron and 2.76 lakh tonnes of billets, will expand its capacity to produce billets, bars, and steel rods of different grades and sizes. It will be a plan set in motion after the Orissa government fulfills its promise of pumping in Rs 95 crore as equity in NINL, which is promoted by MMTC Ltd. along with the state government. For quite some time there was a move for a merger of the 1.1 million tonne capacity integrated iron and steel plant (NINL) at Kalinga Nagar in Jajpur district either by the Steel Authority of India Limited (SAIL) or Rastriya Ispat Nigam Limited (RINL). But now the state government is keen not to dilute NINL’s ownership by contributing its share for developing facilities for steel making. The NINL’s 1.1 million tonne capacity pig iron plant is located at Duburi of Jajpur district. The Orissa government has 26 per cent equity stake in the public sector unit’s total equity of Rs 399.79 crore, while MMTC, being the major promoter, has 49.78 per cent stake in the company. NINL also has a 62.5 mega watt captive power plant. The state government has already invested Rs 421 crore out of the estimated Rs 784 crore required for the second phase expansion and now is required to contribute its share of Rs 95 crore out of the balance
APRIL 2010 | 5
PEOPLE
Nair
Mehta
People on the move With his research interests spread across the analysis of satellite and ground magnetic data, time series analysis, electromagnetic induction in the earth and oceans, and equatorial ionospheric currents and fields, it’s not surprising that geomagnetic scientist Manoj Nair decided to focus on predicting tsunamis. But what’s interesting is that his ‘toolkit’ and possible solution depends on underwater fiber optic cables. Nair has dedicated his studies to the measurement of electric signals emitted by tsunamis and whether these could be used to build a warning system. Engaged in this research project at the U.S.-based National Oceanic and Atmospheric Administration (NOAA), he has now discovered a method whereby tsunamis may be detected with underwater fiber optic cables. He has found that the charged particles in the ocean water interact with the earth’s magnetic field to induce voltage of up to 500 millivolts in the undersea cables that carry Internet traffic. With relatively simple technology, such voltage spikes could serve as a tsunami-warning system for nations that can’t afford other types of sensors. “We have a system of submarine cables already existing. The only thing we probably need is a voltmeter, in theory,” Nair said. The salt
6 | WIRE BULLETIN
in ocean water makes it a good electrical conductor. Positively charged sodium and negatively charged chlorine ions in the solution are free to move. In a large movement of ocean water, these ions are carried across the earth’s magnetic field, thereby creating an electrical field. His work was published in the February issue of Earth, Planets and Space and it quantifies the physics of this lower-cost alternative by building a model of the catastrophic Indian Ocean tsunami of 2004. Nair and his team showed that the voltages induced in the submarine cables would be large enough to measure. “We treat this as a novel idea that we are putting forth, but it still needs to be taken seriously and verified by other groups,” he said. “We estimate that the 2004 tsunami induced voltages of about 500 millivolts in the cables. This is very small compared to a 9 volt battery, but still large enough to be distinguished from background noise on a magnetically quiet day,” he added. Nair obtained his B.Sc. degree from the Mahatma Gandhi University at Kottayam in 1993 and followed this up with an M.Sc. degree in marine geophysics from the Cochin University of Science & Technology in 1997 and a doctorate degree in geophysics from Hyderabad’s Osmania University in 2001. Prior to moving to the NOAA, Nair worked as project fellow at Cochin University of Science and Technology; scientist at the National Geophysical Research Institute at Hyderabad and the Cooperative Institute for Research in Environmental Sciences (CIRES); and research associate at the German Research Centre for Geosciences Telegrafenberg at Potsdam. Kiran Mehta, Chairman and Managing Director, Varun Industries, has been appointed the Honorary Consul of Madagascar in India.
As an international diplomat appointed by the government of Madagascar, Mehta will work toward the enhancement of relations of trade, economy, culture, and science between Madagascar and India. He will partner with the government of Madagascar to raise the GDP of the country and create jobs for thousands with several new business initiatives, a company website reports. Varun’s relationship with the government of Madagascar is due to Varun Petroleum SARL, Madagascar, a subsidiary that has signed a new Production Sharing Contract (PSC) with OMNIS of Madagascar for an offshore gas block covering an area of approximately 13,200 sq kms in the basin of Indian Ocean. According to the agreement, Varun Petroleum SARL will have the right to explore, exploit, and undertake offshore mining in the east coast point of the Sainte Marie region. Meanwhile, Varun Industries, a manufacturer of stainless steel cookware, kitchenware, houseware, and other utility items, received approval from its Board of Directors to set up an integrated, state-of-the-art stainless steel-cum-alloy steel complex at Rohat village near Jodhpur, Rajasthan. The plant will be set up in two phases and will comprise facilities for making stainless steel flats and other high quality stainless steel and alloy steel items including rounds, angles, wire rods, channels, structural, and long products.|WB
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FEATURED CONCEPTS Is India ready for non-lead cables? he answer to such a question, at this stage, is in the negative simply because the awareness level about non-lead cables is at an abysmal low. However, attempts are being made to shift consumer loyalty to cables that are not dangerous to health.
T
Lead has been proven to be harmful to the human body. Given the fact that the Indian cable market is extremely price driven and customer acceptance of lead-free cables at a premium is not an acceptable situation, it must have required a lot of courage for New Delhibased Paramount Cables to apparently be the first such company to manufacture leadfree cables for Indian consumers. “People are increasingly recognising the role that quality cabling plays in ensuring the safety of their homes. Our domestic cables will set new technology and quality benchmarks as the country’s first lead-free cables, besides being zero halogen generation and flame retardant with long-term reliability,” Sanjay Aggarwal, Chairman and CEO of Paramount Cables, told the media during their product’s launch in July 2009.
“People are increasingly recognising the role that quality cabling plays in ensuring the safety of their homes...” – Sanjay Aggarwal –
The Rs 800-crore company pumped in Rs 30 crore to set up a line for its domestic cabling business at its facility in Rajasthan. “Currently, almost 95 per cent of the residential and commercial markets use electrical cables which have lead as a major component. Globally, lead is banned in electrical products but in India the awareness about this issue is pretty low,” Aggarwal said. The market for domestic cables is about Rs 5,000 crore and is growing at 20 per cent annually. Elaborating on how the company has been able to make its way into
an intensely competitive market with leadfree cables, S.K. Suri, General Manager, Paramount Cables, said: “We are using technology imported from the UK and are not charging any premium for lead-free cables. Our primary objective at this stage is to get people to use our cables and realise why it is safer to use lead-free cables.” Paramount Cables has initially launched its product in the Delhi and NCR markets and these gradually would be made available in all the key North Indian markets. “We expect to capture over 10 per cent of the domestic cable market in North India within a year with an initial target of Rs 60 crore of sales,” Suri said. So far the company has catered to industries such as telecommunication, railways, space research, thermal and nuclear power plants, petrochemicals, fertilisers, steel, and electronics. “We are confident that consumer loyalty will begin to switch over to lead-free cables soon. An example is of how we have stopped using paints and petrol with lead content because we now know that it can be harmful to our health,” Suri added.
Impact of lead Lead has long been recognised as a harmful environmental pollutant. In late 1991, the U.S. Secretary of the Department of Health and Human Services called lead the “number one environmental threat to the health of children.” There are many ways in which humans are exposed to lead— through air, drinking water, food, contaminated soil, deteriorating paint, and dust. Airborne lead enters the body when an individual breathes or swallows lead particles or dust once it has settled. Before it came to be known how harmful lead can be, it was used in paint, petrol, water pipes and many other products. Lead affects practically all systems within the body. Lead at high levels (at or above 80 micrograms per decilitre of blood) can cause convulsions, coma, and even death. Lower levels of lead can cause adverse health effects on the central nervous system, kidney, and blood cells. Blood lead levels as low as 10 micrograms per decilitre can impair mental and physical development. According to studies carried out in the U.S. and other developed countries, the effects of lead exposure on foetuses and young children can be severe. They include delays in physical and mental development, lower IQ levels, shortened attention spans, and increased behavioural problems. Foetuses, infants, and children are more vulnerable to lead exposure than adults since lead is more easily absorbed into growing bodies and the tissues of small children are more sensitive to the damaging effects of lead.
The Indian scenario Taking into account the harmful effects of lead and the rising demand for cables in India, industry analysts feel that it is high time the government stepped in to make lead-free cables a compulsion. According to the Eleventh Five Year Plan document of
the Indian government, there is a shortage of 24 million homes in the country. As such, the realty sector is scheduled to grow at an amazing rate (barring temporary slowdowns during global economic downturns) and this will create a strong demand for cables. Moreover, with the government recognising the power sector to be the backbone of sustained industrial growth, robust investments have been proposed toward building up capacities. For India to sustain its GDP growth at more than 7 to 8 per cent, it is estimated that the power sector should grow at least 1.8 to 2 times that of the GDP, translating to an additional of generation capacity by nearly 18,000 to 20,000 MW each year. It is estimated that nearly 3 to 3.5 per cent of investment per MW goes toward power cables. Therefore, with an approximate investment of Rs 40 million per MW, the demand for cables will be in the range of Rs 1.2 to Rs 1.4 million. Power distribution generates the highest demand for cables, reaching approximately 10 per cent of the total project cost.
A WAKE-UP CALL In 1999, recommendations on drafting and implementing a national policy for the prevention of lead poisoning in India were submitted in the form of a ‘white paper’ to the Union Minister for Health and Environment by The George Foundation, a non-profit trust in Bangalore, which had completed an extensive blood screening study in seven major Indian cities. The presentation was made by representatives from the World Bank, World Health Organisation, and the U.S. Centre for Disease Control and Prevention, along with The George Foundation. The study had determined that more than 50 per cent of children below age 12 were experiencing elevated levels of lead in their blood, well above the acceptable limit of 10 mcg/dl. “It has been clearly established that lead poisoning causes neurological damage as reflected in a decrease in IQ and learning ability in children. Significantly elevated levels of blood lead can cause damage to systems and organs such as the heart, kidneys, liver and central nervous system,” the study reported.
A transformer in a residential complex. Combining these two scenarios of demand and the need for safer products, lead-free cables should find quick acceptance in the Indian market. Unfortunately, the reality is different. “It will take some time for Indian consumers to demand leadfree cables and for the Indian manufacturers to start manufacturing them. That is because there is no specification and regulation that compels manufacturers to use lead-free materials for the production of cables. The procurement decisions are entirely driven by cost economics and therefore there is generally no purchase preference for lead-free cables. What is required is government regulation,” said V.K. Bajaj, COO, Uniflex Cables. With its production base at Umergaon in Gujarat, Uniflex Cables, incorporated in 1981, manufactures a vast line of electrical and telecom cables, marketed under the brand name ‘Unicab.’
More buildings, more cables, and an increasing risk factor. Interestingly, it is not as if making leadfree cables calls for complicated technologies or high levels of investment. “No new technology other than compounding of polymer is required. The existing extruders are good enough for using lead-free polymers. Perhaps, technology change may be warranted for the manufacturing of aluminium sheathed (as an alternative to lead sheathed) extra high voltage (EHV) range
Children are more susceptible to the harmful effects of lead. The white paper called on the government to implement effective preventive measures on a national scale. “The government is urged to force changes in long-standing practices in industry and public services—such as eliminating leaded gasoline, testing for lead in water supply, milk, food and other consumer products, and regulating lead in industrial emissions. The proposal outlines an implementation strategy that would result in reducing lead poisoning to acceptable levels within a 15-year time frame, with most of the significant gains made in the initial five years,” the paper said.|WB
of cables and other cables for underwater applications,” Bajaj said. In fact, there may not be any additional cost or difficulty in switching over to lead-free cables. So what is it then that creates this unwillingness to make and supply lead-free cables? Bajaj said, “It is the cost difference because leadfree cables would be priced 6 to 15 per cent higher depending on the size and quality of the cable and that makes a huge impact in a highly price sensitive Indian cable market.”
Make it mandatory The only way out of this insistence on using a product that has been proved to be detrimental to health is the rule of the law. “We, as consumers, are very slow in changing our habits and therefore any switchover takes a long time for successful implementation. continued on p. 8
APRIL 2010 | 7
FEATURED CONCEPTS As has happened in other countries, the Indian government needs to consider the illeffects of using lead in cables on a very serious note and pass a law that will ban the use of cables containing lead. But even if that happens, it is quite possible that in the unorganised market there will be players who will continue to use lead and simply put a tag stating lead-free on the top. Consumers do not have the wherewithal to know how to distinguish between cables with lead and those that are lead-free,” said Mahesh Khandelwal, CMD, Khandelwal Cables, the Vrindaban-based company that manufacturers a wide variety of cables, submersible winding wires, and fiber glass leads.
“An attempt must be made by the community of builders to provide lead-free cables in all homes as part of their insistence on safety. If that happens, manufacturers will quickly start changing over to making lead-free cables.” – S.K. Suri –
A domestic junction box for electricity distribution. However, any move on the government’s part may take long in coming. As Bajaj points out, more than 50 per cent of the cables manufactured in India are used by government utilities and projects and yet there has not been much effort made to introduce any regulation or purchase preference. But there is hope. While Paramount Cables is one company that has taken a pioneering step, some efforts are being made by Indian cable companies who have been trying to introduce lead-free cables as part
8 | WIRE BULLETIN
of their corporate social responsibility. Such cables are now being imported in an exercise to test the waters. “An attempt must be made by the community of builders to provide lead-free cables in all homes as part of their insistence on safety. If that happens, manufacturers will quickly start changing over to making lead-free cables,” Suri said.|WB
wire 2010 continued from p. 3 KEI Industries Ltd. Stall No: 11J06 Products: Wires; ropes; nails; and screws. Email: sswsales@kei-ind.com Macro Bars And Wires (India) Stall No: 17A19 Products: Stainless steel wires. Email: pvaid@mbwindia.com Miktrotek Stall No: 11E06 Products: Wire die polishing machine. Email: mtbgmbh@arcor.net Mohindra Stainless Ltd. Stall No: 11D08 Products: Stainless steel wire. Email: mita.kar@mohindra.asia MPI Machines Stall No: 11J01 Products: Armouring and drawing machines. Email: mpihouse@airtelmail.in Mukand Stall No: 17B49 Products: Alloy, special, and stainless steel. Email: akjain@mukand.com Nevatia Steel & Alloys Stall No: 11D65 Products: Stainless steel wires; wire rods. Email: nikhil@nevatiasteel.com Panchmahal Steel Stall No: 16H04 Products: Steel wire rods; wires; and bars. Email: joachim@panchmahalsteel.co.in Prasum Metals Stall No:16A63 Products: Stainless steel wires. Email: apatel@prasummetals.com Push Up Tools Stall No: 15C11 Products: Carbide wire, tube and draw dies. Email: rajeshjain@pushuptools.com Raajratna Metals Stall No: 12D23 Products: Wires; bars; and springs. Email: raajratna@raajratna.com
Ratnesh Metal Industries Stall No: 17B31 Products: Shaped bars and fasteners. Email: info@ratneshmetal.com Rimjhim Ispat Ltd. Stall No: 12C76 Products: Billets; rods; wires; and bars. Email: ac@rimjhimispat.com Shree Extrusions Stall No: 16D46 Products: Nonferrous wire and rods. Email: ahd@shree-extrusion.com SKM Steels Ltd. Stall No: 17E03 Products: Bars; wire rods; and billets. Email: export@skmsteelsltd.com Sudhir Enterprise Stall No: 9E51 Products: Spools for cables and wires. Email: sudhirenterprise@rediffmail.com Supermac Industries Stall No: 16K19 Products: Extruders, takeups; and payoffs. Email: jasvinder@supermacindia.com Swaraj Technocrafts Stall No: 16C59 Products: Wiredrawing machines. Email: swarajtechno@rediffmail.com Systematic Intel Stall No: 16D44 Products: Armoured and fencing wires. Email: dhruv@systematicltd.com Venus Wires Stall No: 9B02 Products: Fine, coarse, and spring wires. Email: bohrahitesh@gmail.com Viraj Stall No: 9B60 Products: Wire rods; bright bars. Email: hitesh@viraj.com Wirex Dies & Steel India Stall No: 10E26 Products: PCD, natural diamond dies. Email: wirex1@ndf.vsnl.net.in|WB
In India please contact: Source Smart Namdeo Ranjane 206 Stanford Plaza, B65 New Link Road Andheri(W), Mumbai 400053 Telephone: 22-2673-4850 Fax: 22-2673-4851 Email: sourcesmart@gmail.com
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APRIL 2010 | 9
PRODUCTION TIPS Cabling processes Rigid cage strander Rigid cage strander machines are used to manufacture large stranded (multilayer) bare conductors. The reels are fixed in a rotating cage with a center hole for passthrough of cable or strand element. The wires paying off of the reels pass through and exit the cage to the outside along with the central one, through a rotating lay plate and into a closing die where they can then be wrapped around the central element. Several “rotors� with the fixed reels can run in tandem to make multiple counterlay conductors (1+6+12+18, for example) or for serving to wrap protective wire around a cable for mechanical protection. The rigid cage strander imparts foretwist to the cabled elements. See Fig. 1.
Fig. 1. Rigid strander reel orientation.
Planetary cabler This machine is similar to the rigid strander except that the elements, paid off from reels which orbit the central machine axis (cable path), are set in cradles that are fixed by the transmission so that the absolute
10 | WIRE BULLETIN
rotation of the reel axis is zero. In other words, the axis of the reel is always positioned horizontally as it rotates about the
Fig. 2. Planetary cabler reel orientation. central cable path. The ability of the planetary cabler to lay up cable around the central element, without rotation of the orbiting reels, means that no twist is imparted into the elements. In this case, the reel axis is always held horizontally and one full backtwist per revolution is given. Some transmissions for the reel cradle have been designed to rotate the cradle (reel axis) proportionally to the rotation of the machine frame so that variable backtwist, more or less than 100% may be imparted to the cable. This machine can be used to cable elements that have springback, such as when armoring with high tensile steel, and may require over twisting to compensate. For example, a backtwist of 105% may be required. Planetary stranders must rotate the reels around a central axis and are therefore high inertia, lower speed machines, but usually give the best quality when backtwist is necessary. This is a popular device to use in applications where increased flex is needed, such as the assembly of fiber optic cables. See Fig. 2.
Tubular strander This machine comprises a rotating steel tube supported by encircling bearings with the reels held inside the tube in bearing mounted cradles that are counterbalanced to prevent rotation. The wire travels from the reels, through the cradle bearing, to outer periphery of the tube where it passes through guide dies. The wire travels along the tube and passes through a rotating lay plate and then into a closing die, pulled forward by an external capstan. These machines are mainly used to produce counter-laid concentric conductors of aluminum or copper and they can be used for steel strands. For cabling, they are frequently used to armor the cable by wrapping steel strands around the outside of a cable, forming mechanical protection. They are rarely used for insulation material. See Fig. 3
Fig. 3. Tubular stander configuration.
Double twist cablers The double twist cabler machine is commonly used to manufacture bare conductors and cabling. For each single revolution of the rotor, two twists are imparted to the elements. A double twist machine consists of a bow with eyelets or rollers through which the cables pass, and the take-up reel
mounted inside the bow path. The elements are closed before reaching the bow, where the first twist is formed. The second twist occurs in the bow and is completed as it leaves the second pulley. If high pulling force is required pulling capstans move the cable in a linear fashion, otherwise the cable may be hauled off directly by the reel rotation.
Fig. 4. Double twist cabler schematic. A disadvantage of double twist cablers is in the application of concentric taping on insulated cabling because the tape is usually severely distorted by the stress of the second twist. In such instances, a pretwister can be used to literally reverse twist one time before the taping applicator. This process limits the maximum operational speed and can make the single twist processes more desirable and economical. Double twisting is the predominant process for twinning or small conductor count cables. See Fig. 4.|WB Source: Electrical Wire Handbook: Part 2, Chapter 10 available through www.wirenet.org/waistore
PRODUCTS, MEDIA, & TECHNOLOGY Products Device provides precise diameter measurement SIKORA AG introduces its new LASER Series 6000 precision diameter measurement device that expands the company’s diameter gauge product family. A company release reports technical improvements in the device including the capability to take 2,500 measurements per second with extremely high single value precision, repeatability, and accuracy. Another engineering enhancement increases the gauge openings to twice the size of the measuring range to ensure easy and safe cable feed through, the release said. Highlights also include: a pluggable universal interface module for all connections integrated directly into the gauge head; and a swivel design that allows the gauge head to be moved up easily, out of the extrusion line. The measuring axes are arranged with the gauge open at the bottom to prevent debris and water from falling into the measuring area, the company reports.
The new LASER Series 6000 from SIKORA. The product series includes the LASER 6020 XY model for product diameters from 0.25 to 20 mm, the LASER 6040 XY model
for measurement ranges between 0.5 to 40 mm, and the LASER 6080 XY model for products from 1 to 80 mm. For further details contact: SIKORA INDIA, 1/36, 1st floor, Mall Road, Tilak Nagar, New Delhi – 110018, Tel.: +91-114144-7913, E-mail: sikoraindia@gmail.com.
110054, Tel.: +00-91-11-23977762/23973240, Fax: +00-91-11-23914179, E-mail: richard. diamondtools@gmail.com.
Richard Sales offers die polishing compounds
Gurgaon-based Grid India Power Cables Private Limited (GIPC) announced the launch of its website www.gridcables.com, stating that it would be of help to its customers to gain information about its wide range of products. Established by Rajesh Gupta, the company is an ISO 9001:2008 certified manufacturer of power cables, up to 132 kV, which includes expansion in medium- and low-voltage cables, including LT PVC/XLPE power cables, PVC cables, PVC insulated cables, PVC electrical cables, control cables, AB cables, and instrumentation cables. These cables cater to the needs of a diverse portfolio including domestic, infrastructure, and industrial applications. The company has manufacturing facilities at IMT-Manesar, Gurgaon and Bhiwadi (Rajasthan) that are equipped with
Richard Sales Corp. has developed die and mould diamond polishing compounds and powder for hand lapping of dies, mould cavities, and various hand polishing applications. The abrasive material is blocky in shape and comprises fragile diamond particles for scratch-free finishing and excellent cutting properties to reduce normal processing time. Fine diamond particles are dispersed within the compound for even distribution. The compound is non-toxic, non-hazardous, and safe to use for hand polishing and machine applications and can be stored for years in any environment. The compound is available in 5 gms syringe packaging. These are for stock removal (rough), medium polish, and then final mirror polish for any metal. The company also manufactures all types of diamond tools. For further details contact: Richard Sales Corp., 24, Rajpur Road, Civil Lines, Delhi-
Media GIPC launches website
ASK THE EXPERT
continued from p. 1
Q: How can the diameter of a closing
die in front of a double twist buncher be determined? With bunched wire constructions that have an odd number of wire ends, how is the finished diameter determined? Once the theoretical diameter is established, how much larger is the die opening? E.g., Annealed copper wire - .080" diameter x 4 ends or aluminum wire - .072" diameter x 5 ends.
A:
The theoretical diameter of the stranded conductors going through the die is mathematically determined as shown below.
Number of wires
Technology Micro-Duct fiber optic cables ease installation With fiber-to-the-home (FTTH) finally emerging into the mainstream and all set to transform the telecom environment worldwide, Pune-based Sterlite Technologies has recommended that the network installer use micro-duct fiber optic cables in their FTTH installations. These very small diameter, lightweight, and flexible cables can be airblown into the existing ducts with sub-duct size of 10/12 with a blowing pressure of maximum 12 Bar for a distance of up to 2 kms.
Multiplier
2 3 4 5
2 3 4 5
2 2.16 2.42 2.7
6
6 around a dummy core
3
7 8 10 12 14 15 16 machines for insulation, pair screening, cable laying up, overall screening, inner sheathing, armouring, outer sheathing, final testing, and packaging.
Construction
17
1 center, 6 around 1 center, 7around 2 center, 8 around 3 center, 9 around 4 center, 10 around 5 center, 10 around 5 center, 11 around 1 center, 6 around, 10 around
3 3.33 4 4.16 4.42 4.7 4.7 5
18
1 center, 6 around, 11 around
5
19
1 center, 6 around, 6 around
5
The 19 strand wire construction can also run as a smooth, round unilay construction, using a shorter lay. The multiplier is then 4.8736. The die diameter is 2% larger than the calculated number. Excerpted from www.wirenet.org/forum/ Determine multipliers beyond 19 strand wire construction and compare the diameter difference between single- and doubletwisted construction of several popular sizes through article number 3257: “Single-twist bunching,” by F.B. Krafft, available through the Wire Association International’s comprehensive online library of technical articles published from 1926 to present. Visit www.wirenet.org/technical/ abstract/abstract.cfm.
This enables ease in blowing of the cable through the pre-lubricated ducts as also expansion of the network with minimal costs, as the micro-duct cable can be installed within the existing free space of ducts by putting the sub-duct in the main duct. The cable has a specially developed low shrinkage high-density polyethylene sheath with normal thickness of 0.5 mm and can accommodate a fiber count in excess of 72°F. According to Keith D’Silva, Head of Corporate Communications at Sterlite Technologies, “The Micro Duct-Lite Cables were found to have entirely alleviated the need and cost of trenching. As the weight of these fiber optic cables is about half of that of conventional ones with the same
fiber count, it improved the cable blowing efficiency and considerably improved installation costs.” Manufactured by Sterlite Technologies, the cable can withstand temperature extremes from -20°C to +70°C. They also enable mid-span access since they have a minimal bending stiffness with no preferential bending plane so that the cables can be installed in the most extreme high cable density situations. For further details contact: Sterlite Technologies, 4th Floor Godrej Millennium, 9, Koregaon Road, Pune 411 001 Maharashtra, Tel.: +91-20-30514000, Fax: +91-20-26138083, http://sterlitetechnologies.com.|WB
APRIL 2010 | 11
TECHNICAL ARTICLE Twist and tension Understanding the role of these two key elements can help a manufacturer determine an optimum manufacturing solution from the range of process alternatives. By Andy Blackmore
Introduction Twist occurs in every element, in any process, takes place during cabling, stranding, closing, and serving. How much twist and whether it affects product performance are the issues. Tension affects the distribution of twist in the process, specifically, the preset tension and the uniformity of that tension. Each has an effect on the other. It is the management of both these parameters that provides the best results. This article covers these elements as factors in developing the optimum manufacturing solution.
Definitions There is no universally accepted language for much of this subject. The following definitions are used here for consistency. Twisting. Refers to the twisting of each element, around its own axis, in the process of continuously spiralling single or multiple elements. Twist units. The unit of twist for each payoff component is measured in degrees, which quantifies the amount of twist, for each lay length, of the spiralled assembly. Planetary assembly. Refers to a family of machines that are designed to minimize the degree of twist in each component during the twisting process. Europeans refer to this family as “machines without backtwist.” In this planetary assembly process the degree of twist is close to 0 degrees, around its own axis, for each lay length. Rigid assembly. In contrast to the planetary assembly, the rigid assembly imparts close to a full twist (360 degrees) around the axis for each lay length. Europeans refer to this family as “machines with backtwist.” Lay angle or pitch angle. This is the angle of application of the individual components in the twisted assembly. Degrees are also used for this unit of measurement. It is the natural angle of the individual element, in the closing process, from the axis of the twisted assembly. Variable backtwist. Refers to machines that have the ability to compensate for the “lay angle” twist component.
duce a little or a lot of twist. The amount is proportional to the lay angle. Further, there is a point where the degree of twist is the same whether the machine is planetary or rigid. This point occurs where the lay angle is 60 degrees. Note that although the twist rate is the same, the direction of the twist is opposite. Common reference points include specifications that have language similar to: a) the length of lay must not exceed 15 times the assembly diameter; or b) the lay length of lay must not exceed 40 times the diameter of each component. These criteria dictate the lay angle or range of lay angles allowed. Even when there is no specification, lengths of lay are chosen with similar lay angles to ensure that the assembly is flexible and the construction remains stable for the subsequent operations.
Tension The optimum process tension is related to the properties of the material and the diameter, or section, of that material. Stress in the element is a good starting point to determine this value. The level of stress will be different depending on the twist requirement of the process. This stress or tension is one component that provides the energy that is used to permanently twist the product. Furthermore, this stress or tension is higher as the degree of twist increases. A simple comparison would be the tension required to keep a product with zero twist straight versus a product that is twisted a full 360 degrees for each lay length. There are instances in which the optimum tension, combined with the process twist, is not enough to provide the best product. An example is in the assembly of Milliken conductors where it is desirable to have additional torque on the assembly to fully close the elements prior to taping. The torque required to assist closing is insufficient with tension alone. In this example a rotating caterpuller is added to provide addional torque; the track idles and the rotation is driven. See Fig. 2.
Twist The relationship between pitch angle and twist is a simple geometric function. See Fig. 1.
Fig. 2. Line layout of Milliken stranding line.
Fig. 1. Graph of product twist versus lay angle, two curves. What is evident is that, in the extreme, both rigid and planetary machines can pro-
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be better controlled in the finished cable with a driven pretwister (or variable speed assembler). In this instance, the final closing—which occurs naturally after the return sheave in a double twist machine—is brought outside with the assistance of the pretwister. This redistribution of the natural twist of the process allows metering of the tape more closely associated with the final lay of the twisted assembly. See Fig. 3.
It is also desirable to over twist or under twist the assembly when other functions are performed in the line. This is generally when natural distribution of twist in the process does not give the best control. An example of this is a double-twist tape shielding line where the tape tension can
Fig. 3. Tape shielding line layout.
Twisting machines Twisting machines can be classified by the principle they use. The following three segments differ in the degree of twist imparted to the individual element. Planetary machines (+) impart almost no twist to the element. These include: • planetary cage strander/cablers; • bow twister/cablers; • skip strander/cablers; • tubular strander/cablers; • stationary payoffs; • stationary take-ups; and • SZ equipment. Rigid machines (-) impart significant twist to the element. These include: • rigid cage twisters; • flyoff cage twisters; • single twist; • double twist; • rotating payoffs; • rotating take-ups; • flyoff payoffs; • static spoolers; • bundlepackers; • stem take-ups; • taping heads; • binding heads; and • filling heads. Auxiliary machines (0) have no resultant influence to the twist of the elements. These include: • caterpullers (rotating or stationary); • capstans (rotating or stationary); • pretwisters or variable speed assemblers; • torsion blockers; and • wire guide systems. Rigid systems work because the twist leaks into the cabled product. Gaining a sense of this mechanism is key to enhance the product quality and to realize its operational speed potential. Uniform twisting resulting in uniform bleeding of the twist into the product is generally pre-
ferred, accumulating twist and random releasing that accumulated twist can result in unwanted process challenges.
Hybrid lines All process lines are hybrid lines in that they use more than one of the above components. Combining machine types in one process line can take a planetary assembly and make it a rigid assembly. Similarly, taking two rigid machines, appropriately configured, can make a planetary machine. One analogy is to assume that a planetary machine is a (+) and a rigid machine is a (). If you put two (+)s together the result is a (+) and the assembly remains planetary. In contrast if you put two (-)s together, suitably configured, one can get a (+) or a planetary assembly. The permutations and combinations of the above machine components create numerous options that multiply with the different costs associated with each machine type. Defining the degree of twist that each element can withstand without compromising performance, or the desired degree of twist, leads to the optimum solution. Below are five examples. A traditional planetary cage cabling line. A pure planetary cabling line consisting of a planetary cage (+) and stationary take-up (+). Both are planetary or (+)s. The result is a (+), i.e., the assembly is close to zero twist around the axis of each element. The only twisting that occurs is associated with the lay angle. The introduction of the variable backtwist feature—where the cradle is driven at a rate slightly less than the cage but in the opposite direction to the cage rotation—will correct for that twist. See Fig. 4.
Fig. 4. Planetary cabling line layout. Traditional drum twister or universal cabler. Rotating payoffs (-) with a rotating take-up (-). Both are rigid or (-)s and if configured in the same direction at the same rotational speed the assembly becomes planetary (+) and the only twisting that occurs is that associated with the lay angle. An adjustment to the speed of the rotating payoffs can provide compensation for this twist. Note: a line with single twist payoffs (-) with a single twist take-up (-) is similar to the traditional drum twister and noteworthy in that it is a more cost-effective solution for smaller and generally more flexible products as compared to the larger and more rigid assemblies associated with the drum twister. See Fig. 5. continued on p. 14
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TECHNICAL ARTICLE
Fig. 5. Drum cabling line layout (planetary).
Seven wire ACSR. This conductor has a high tensile steel center wire with six aluminum wires stranded around the steel core. The steel core’s physical properties enable it to resist any degree of twist in the process. The aluminum, in contrast, is very soft and can easily cope with the twist without issue. Because of the steel wire, the traditional approach is to use a tubular (+) or bow/skip strander (+) with a stationary take-up (+). Both are planetary and, as a consequence, there is close to zero twist around the axis of each wire in the stranded conductor. See Fig. 9.
Fig. 14 shows an example of a Single Input Wire (SIW) schedule that covers a wide range of finished conductor sizes with a single drawn input wire diameter.
Fig. 11. Bow twister inside swing of a double twist payoff. Approach two. This method uses a single twist inside the swing of a double twist payoff. See Fig. 12. The single twist approach uses almost identical wire paths for each of the wires with a preloaded dancer controlling directly the tension in each wire. Dancer feedback to the speed of the bobbin drive ensures constant tension in the process.
Stationary payoffs (+) with a rotating take-up (-). This process combines a planetary and a rigid component. Effectively there is close to a full 360 degrees of twist around the axis of each element in the assembly process. See Fig. 6.
Fig. 9. Tubular stranding line layout.
Fig. 6. Drum cabling line layout (rigid). Stem payoffs (-) with double twist takeups (-). Exiting the stem there is a twist proportional to the circumference of the stem’s capstan take-up. This twist combines with the twist of the double twist take-up and results in a significant twist around the axis of each element in the assembly process. See Fig. 7.
The double twist machine is a more costeffective machine for seven wire stranding if one compensates for the twist in the steel wire. A suitably configured double twist payoff (-) can do this. By using two (-) machine components one can produce a (+) for one of the seven elements in the assembly. This approach has other advantages, notably the ability to use the large capacity stem payoff and the continuous payoff possibilities for the aluminum strands. See Fig. 10.
Fig. 10. Double twist stranding layout. Fig. 7. Double twist stranding line layout. Concentric stranders. Concentric stranders (-) with stationary take-up (+). The concentric strander is similar in principle to a single concentric taping head but it has multiple packages mounted on the same shaft. There is a significant twist around the axis of each element in the assembly process. See Fig. 8.
Fig. 8. Concentric stranding line layout.
How to use this information This segment applies the above elements to making two products: seven wire aluminum conductor steel reinforced (ACSR) strand and category/data cables.
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Category 6e/data cables. This is a fourpair construction in which all four pairs are cabled together.The product parameters that determine performance require that each element be twisted around its own axis prior to being twinned. Variable backtwist describes this rotation. This is an instance where twist around its own axis is desirable. Two approaches can be used for this process and present a good example of how different components can be used in tandem to streamline the manufacturing process. Approach one. This method uses a bow twister inside the swing of a double twist payoff. See Fig. 11. It combines the planetary assembly of the bow twister to creating a twin. This planetary assembly is then twisted as a twin with the rigid assembly of a double twist machine. Note that with a planetary assembly the wire rotates relative to the adjacent wire when the wires are twisted together. The bow twister approach uses substantially different wire paths for each of the payoff wires and compensation. Tension for the different paths is achieved with tension sensors. One sensor reads the single bobbin outside the bow. The second reads the tension on the twinned wire. Both sensors provide feedback to the wire payoff drives.
Fig. 14. Single Input Wire (SIW) strand schedules.
Conclusions Twist and tension remain key elements in the determination of the optimum manufacturing solution. Knowledge of the physical properties of each element can make a significant difference, not only in evaluating alternative processes but also in the overall cost. This knowledge combined with the range of constructions allowed by the current specification, and their proposed revisions, represents the challenge in determining the optimum manufacturing solution.|WB
Biographical Information Fig. 12. Single twist inside swing of a double twist payoff. The desired variable backtwist is achieved in both instances. Product performance and cost per performance will determine the solution of preference. Often the traditional analysis is challenged by product designs. It is sometimes difficult to determine which comes first: the change in product design that allows more costeffective manufacturing technology; or the change in technology that prompts a product design change. The cost-effective multi-wire wiredrawing process is one obvious example, another is the use of stems as a bare wire package for subsequent bunching/stranding. Both have encouraged solutions that minimize the number of drawn wire sizes that cover the desired range of conductors. This Single Input Wire (SIW) methodology is gaining widespread use for both bunched and stranded copper and aluminum conductors. Double twist, single twist, and concentric rigid stranders are commonly used with these strand/bunch schedules reporting significantly higher drawing throughputs due to shorter set-up times with substantially lower bare wire inventories to manufacture a range of conductors. An example of a single twist line that strands conductors up to 500 mm2 or 1000 kcm is shown in Fig. 13.
Fig. 13. Single Twist Stranding Line.
Blackmore Andy Blackmore is a principal of Roteq Machinery Inc., Toronto, Canada. He has spent the past 35 years developing and promoting rotating equipment solutions for the wire and cable, steel rope and flexible pipe/hose industries. This paper was presented at Interwire 2005 in Atlanta, Georgia, USA, May 2005 and updated in early 2010 for the WIRE BULLETIN.
PERSPECTIVE A D V E R T O R I A L
Fluoro-Polymer Extrusion for Micro-Coax, LAN and Coax Cable Insulation
Extrusion with RKF 2.2 F crosshead. Rosendahl, with more than 30 years of experience in fluoropolymer extrusion, has developed and designed equipment and production lines for high efficient insulation and jacketing with fluoropolymers. A wide range of specialized lines are available for solid and foamed insulation of high performance cores.
The technical specifications for a MicroCoax line are shown in Table 1. The following components are required for Micro-Coax manufacturing. Tension control. Precise and uniform tension control—with very narrow tolerances— is needed on pay-off and take up units. Extruder configuration. This requirement depends on the properties of the desired finished product i.e., single layer; foam– skin; or skin–foam–skin. Main extruder. A Rosendahl gas injection system is specified for the main extruder unit. Crosshead design. Specific cross head designs include a miniature crosshead style that accepts standard 4/6 extrusion dies with miniature tip inserts. Its capability for low melt volume minimizes scrap and its hydraulically controlled bypass valve optimizes foaming start up and product changes. It features a three-stage cooling trough design for solid insulation that includes an air gap and both hot and
Product segments covered by specially designed equipment are: Micro-Coax: with solid or foamed insulation, AWG 48 – AWG 30. LAN: CAT5, CAT6, CAT7 and higher with solid and foamed insulation. Mini-Coax: Typical RG-Type products with triple layer skin-foam-skin insulation.
Conductor
Cu, Cu Alloy, plated Cu
Diameter range
1 x 0,025 - 7 x 0,12 mm AWG 50 - AWG 30
OD range
0,09 mm - 1,50 mm
Material
PFA, FEP, solid or foamed, max. 50% foamed
Line speed
geared for 300 m/min.
Tension range
0,15 N – 5 N ± 0,03 N
Wall thickness
min. 120 (solid 30) µm
Table 1. Technical specifications for a Micro-Coax line.
MCX Wire 7 x 0,0254 mm ± 0,5 % Foamed FEP 5030 0,33 mm ± 1,5% 93% 40 m/min. 50% Medical Wire Diameter of conductor 0,04 mm ± 0,5 % Product design Solid PFA 420 Overall diameter 0,11 mm ± 1,5% Centricity 93% Production speed 80 m/min. Diameter of conductor Product design Overall diameter Centricity Production speed Foam rate
Table 2. The typical products on a Micro-Coax line.
cold water for cooling. Lastly the design includes a fluoro-resistant precision vacuum pump that works in accordance with the Venturi principle. The vacuum is generated by means of precisely controlled compressed air.
The company also offers equipment for speciality cables and conductors for aerospace and medical applications; oilfield pump cable insulation; heater cables; and more.
The typical products that can be produced on a Micro-Coax line are shown in Table 2. Contact: www.rosendahlaustria.com.|WB
Micro-Coax RE 20 extruder.
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CLASSIFIED & AD SHOWCASE
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