NOVEMBER 2009
Rs. 125
WIRE BULLETIN India’s Quarterly Bulletin Dedicated to the Wire and Cable Industry
ASK THE EXPERT Q: What calculation is needed, if any, for the proper percentage between dies?
See answer on p. 11
Q: How many feet of cable can a reel hold?
Mumbai bridge is India’s first and longest sea link Wire and cable from two companies in India are among the key elements that are part of the Bandra-Worli Sea Link (BWSL), which has been hailed by some as a modern engineering marvel. BWSL is the first and longest sea-link bridge in India, connecting Bandra and the western suburbs of Mumbai with Worli and central Mumbai.
See answer on p. 11
NEWS BITES • Alpha Wire targets solar market. New photovoltaic wire and solar cable enhances reliability in solar applications.
An overhead perspective of the BandraWorli Sea Link.
The following detail comes from news accounts and press releases: The project is designed to reduce travel time between Bandra and Worli from 45 or more minutes to less than 10 minutes. The four lanes of the inner side of the bridge were opened in June and the outer lanes are scheduled to open by year’s end. The BWSL’s cable-stayed main bridge spans some 600 meters in length and is 126 meters high, making it the equivalent of a 43story building. The bridge was fastened by 132 pieces of stay cable from Shanghai Pujiang Cable Co., Ltd., which supplied a total of 424 finished cables, including those for the uncompleted outer bridge. The approximately 2,250 km of highstrength, galvanized steel wire used to continued on p. 3
• El Sewedy launches state-of-the-art website: www.elsewedycables.com.
Harley-Davidson motorcycles to be sold in India
• Nexans wins a cable contract for ice-resistant cable from Sevmash to equip an oil production platform in the Barents Sea.
A slice of American heritage may soon be seen on the streets of India. HarleyDavidson Inc. announced that it plans to sell its legendary motorcycles next year in India, which it notes represents the world’s second-largest market for motorcycles. Harley reports that it sees a growing economy, rising middle class and investment in highways as leading to more leisure motorcycle riding in the country, which should translate to sales of its large, powerful models. Anoop Prakash is managing director of Harley-Davidson’s new India unit, which seeks dealers for Mumbai, Delhi, Bangalore, Hyderabad, and the state of Punjab. Motorcycle sales for the top 12 brands were reported to be down 46% in the first six months of 2009 from the prior year, while motorcycle sales in India rose about 15% in four months to July.
QUOTEABLE QUOTES Quality has to be caused, not “controlled.” ~ Philip Crosby Almost all quality improvement “comes via simplification of design, manufacturing...layout, processes, and procedures.” ~ Tom Peters Winners make a habit of manufac“turing their own positive expectations
“Given the rapid development of India’s economy and physical infrastructure, this is exactly the right time,” Harley COO Matthew Levatich said in a statement.
Many motorcycles sold in India cost $1,500 or less, while the Harley-Davidsons, which list for $15,000 and up, will also carry an import tariff that can nearly double the price. Total sales are projected continued on p. 3
in advance of the event.” ~Brian Tracy
KEC Int’l & RPG Cables to merge
IN THIS ISSUE: Editorial .............................. 2 World Calendar ................... 3 Industry News ..................... 4 People ................................ 6 Featured Concepts .............. 7 Production Tips ................. 10 Products, Media, & Technology..................... 11 Technical Paper................. 12 Classified & Ad Showcase.......................... 16
KEC International Limited (KEC), a global power transmission project management company involved in engineering, procurement, and construction, announced that its board of directors approved the merger with RPG Cables Limited (RPGCL) of India, a manufacturer of power, control, telecommunications, and instrumentation cables. The merger date is March 1, 2010. KEC has global operations in 20 countries including India and currently consumes cable products in its distribution, railway, and telecommunication project management businesses. The merger is said to provide the in-house capacity to produce the cable products needed for these businesses, which can further KEC toward becoming an integrated infrastructure project management player. In published reports, KEC International chairman Harsh Goenka, noted the expected benefits of the merger. “This merger
is a natural extension of KEC’s role in the energy space and a key element in the energy distribution portfolio that KEC is building into its strategy. Besides, there are obvious and distinct synergies which it will provide,” he said. With the company’s global presence and resources, KEC can expand its cables business in capacity and geographical reach. Commenting on the merger, Ramesh Chandak, MD & CEO, KEC International Limited said, “Just as our own tower manufacturing capacities have given a thrust to our transmission business, the merger provides us with cable capacities which will support our distribution, telecom and railways business substantially.” RPG Cables Ltd. has manufacturing facilities in India. RPG Enterprises has more than 20 companies managing business interests in power, tire, transmission, IT, and carbon black.|WB
CII study highlights future of Indian power sector
A recent report by the Confederation of Indian Industry (CII), entitled “Sustaining Growth: Future of Indian Power Sector,” revealed the emerging opportunities and notable challenges for the future power markets. The A.T. Kearney study describes the evolving Indian power market from one that is “opening” to one that has quickly moved into a “developing” phase due to the steady increase of power demand, which is expected to grow at a steady 7.5-8% CAGR until 2017. According the study, India’s low power penetration levels are an indication of substantial unmet demand requiring consistent rates of high growth to meet comparable consumption levels of developing countries like China and Brazil. Sudhir Trehan, Chairman - CII India Energy Conclave & Energy Expo, and Managing Director, Crompton Greaves was quoted in a press release; he said, “The emerging dynamics of the Indian power market would require industry players to realign their strategies and operating models to the changing sectoral trends. The focus would need to be both on project execution as well as efficient operations, in line with the ‘growth’ characteristics of the sector.” New business opportunities in gas, hydro and nuclear energy and a renewed interest in coal as the dominant generation fuel were highlighted in the report. Renewable energy is expected to continue to grow at 15-20% per annum and government incentives will encourage solar farms and photovoltaic (PV) cell manufacturing interests. Similarly, the report points out that annual wind energy supply will continue to grow 15-20% with new offshore capacities and large capacity turbines. Generally the provided descriptions offer a cautiously optimistic view of India’s power sector and its ability to support the country’s growth objectives. “A new era of ‘Power on Power’ compensation will emerge by 2014 that will bring in a least 80-85 GW of new capacity,” said Kaustav Mukherjee, a partner at A.T. Kearney.|WB A D V E R T I S M E N T
NOVEMBER 2009
EDITORIAL
O
ver the past two years our readership has grown and with it so has the thirst for coverage of industry news affecting Asia’s vital wire and cable sector.
Publisher | Steven J. Fetteroll Contributing Writers | Mark Marselli and Mahesh Poddar
I’m delighted to introduce you to the newly expanded Wire Bulletin format and to this introductory issue. The publication’s editorial mission is steadfast. Our focus is to inform you. Our aim is to engage you. And we intend to accomplish both with the quarterly publication of newsletters like this one, which will commence official publication in January 2010. In this issue, and in those to follow, we will cover Asia’s wire and cable market from the inside out giving you compelling reasons to read on. We’ll introduce you to the people—not only the machines or processes—who bring energy, experience, and achievement to business here and around the globe. Also count on regular sections that reveal industry news and business trends; product debuts; personnel appointments; and how-to process solutions. Or venture into the lab to learn scientific findings in a technical article excerpt that begin on page 12. As you explore the reports that occupy this publication you will see that Wire Bulletin offers both topical and in-depth news in a flexible style that encompasses subjects to interest readers from technical specialists to CEOs. In fact, if you’re new to the field check the world calendar on page 3 to find out where you need to be. Or take a look at the “Ask the Expert” section on page 1 to discover the answers to questions that are frequently asked but seldom documented. This is your news forum and it is shaped by an increasingly active community of participants. Wire Bulletin is poised to widen your views. On strategy. On innovation. On alliances and collaboration. All are newsworthy high notes worthy of investigation. If you like what you see on the pages of this publication, tell us. If you have an article idea, suggest it. News releases? Let us hear from you. If it is industry related we invite you to introduce it. Explain it. Or even question it. We pledge to do our part to share it.
Mahesh Poddar WAI Board of Directors Representative | 2009
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WIRE BULLETIN Director of Marketing Services | Janice E. Swindells Graphic Artist | Adrienne E. Simpson WIRE BULLETIN is published quarterly by Wire Journal International, a wholly owned subsidiary of the Wire Association International, (WAI) Inc. ©2009 by Wire Journal International. 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 WAI, 1570 Boston Post Road, P.O. Box 578, Guilford, Connecticut, 06437 USA. Tel.: 203-453-2777; e-mail: sfetteroll@wirenet.org; web site: www.wirenet.org Printed in India. The publisher of Wire Journal International 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 the Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA. POSTMASTER: Send address changes to WAI, 1570 Boston Post Road, P.O. Box 578, Guilford, Connecticut, 06437 USA.
CALENDAR & FRONT PAGE NEWS Polycab selects InnoVites for operations software
WORLD CALENDAR
between 75 and 140 metric tons. Those segments form the bridge from the Bandra end to the Worli end, a distance of 4.7 km. The electrical cables were provided by India’s Polycab Wires Pvt. Ltd.
January 20-24, 2010: ELECRAMA 2010 Mumbai, India. The ELECRAMA 2010 trade fair (Bombay Exhibition Center) showcases electrical, electronics and power products, by exhibitors involved in transmission, distribution, protection and utilization of electrical power; equipment for generation, instrument transformers, equipment for process control, winding wires, testing, monitoring and recording, fixtures, decoration, equipment for telecommunication, lighting equipment, computer hardware and software, solar energy system, water heaters and energy conservation equipment. Visitors include raw material manufacturers, importers and exporters, traders, contractors, publishers, consultants; professionals from associations, power utility, government, department, and purchasing organizations. For more information, contact the organizer: the Indian Electrical and Electronics Manufacturers Association (IEEMA). Contact: IEEMA | www.ieema.org
February 9-11, 2010: Middle East Electricity Exhibition 2010 Dubai, India. Supported, by the UAE Ministry of Energy, the 35th Middle East Electricity exhibition will run from February 9-11, 2010 at Dubai International Exhibition Centre. All sectors of the energy industry will be comprehensively covered, with focus areas including water, lighting, new and renewable and nuclear energy, bringing essential expertise to the region. Contact: IIR Middle East | ww2.iirme.com
April 12-16, 2010: wire Düsseldorf Düsseldorf, Germany. To be held at the Messe fairgrounds. Contact: Messe Düsseldorf | Tel.: +49 (0) 211 4560-240, www.messe-duesseldorf.de
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
Polycab Wires, Mumbai, has selected InnoVites—a software development company, with offices in India and The Netherlands—as its partner to implement CableBuilder©, a popular cable design software by Cimteq Ltd. Polycab Wires will use CableBuilder to improve the quality and efficiency of its design and quotation processes. Bharat Jaisinghani, a Director at Polycab, said “InnoVites understands our business and also has a proven capability to deliver effective IT solutions for the cable industry. Supported by their knowledge and skills we are able to achieve the maximum benefits of CableBuilder.” Polycab Wires is a leader in the manufacture of cables and wires in India and it exports its products to countries in West Asia, Europe, and Africa. Contact: Polycab Wires, Tel.: +91 22 2432 77070, info@polycab.com, www.polycab.com.|WB
Mumbai bridge continued from p. 1 support the cable-stayed bridge weighs about 20,000 metric tons. The Wire Division of India’s TATA Steel supplied the low relaxation pre-stressed concrete (LRPC) strand used for the 2,353 pre-cast concrete segments that each weigh
A cutaway view of bridge cable. The bridge as a whole weighs 670,000 metric tons, the equivalent of 50,000 African elephants. The steel wire used in the project could circle the earth, with each cable designed to take a weight of 900 tons. The project force includes engineers from India, Britain, Canada, China, Egypt, Hong Kong, Indonesia, Philippines, Serbia, Singapore, and Switzerland.|WB
Harley-Davidson continued from p. 1 to be less than 1,000 a year, a very small number compared to the 7.4 million sold in the most recent year. At the same time, Harley-Davidson is counting on the attraction of its brand to find buyers in India. An on-line article in The Wall Street Journal, cited one reaction. “It’s very manly; it’s powerful…it makes no sense if you are going through traffic and potholes. But if you can afford to buy a Harley, you can afford to use it when you feel like [it],” said Karun Menon, a Pune resident and owner of a 180-cc engine motorcycle.|WB
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 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 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 who want to attend the most important business week for wire and cable in the Americas. Interwire is the largest and longestrunning wire and cable marketplace in the Americas where buyers, sellers, researchers, and speakers 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
June 19-23, 2011: JI Cable Versailles, France. This multi-organizer 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
hat mation t r o f in e v a Do you h his section? in t to: belongs by e-mail it m b u s rg. Please wirenet.o @ in t e ll u wireb NOVEMBER 2009 | 3
INDUSTRY NEWS Indian CEO addresses World Steel Association Conference Below is the Oct. 12 speech by Lakshmi Mittal, Chairman and CEO, ArcelorMittal, who had served as chairman of the board for World Steel. The speech has been edited for length.
Mittal Good morning everyone and welcome to Beijing for this year’s World Steel Association Conference. It is now one year since we last all met together in Washington. At that time events were unfolding in real-time and none of us could have been certain of the circumstances in which we would meet again in 2009. Indeed the expectations of many were that the crisis would primarily be financial in nature and largely affecting the U.S. and other major financial centres. Fortunately the U.S. Senate (passed the stimulus package)..., giving some much needed economic and financial support. Equally important was the coordinated nature of action taken by a host of countries. (As) we know now, the crisis was not purely financial. In fact, the economic impact was global and some of the most severely affected economies were those with large manufacturing sectors with a dependence on steel and steel containing goods. It has been a difficult time for all of us. The situation would no doubt have been considerably worse had the industry not
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significantly restructured over the past decade. Stimulus plans are taking effect; stock markets have delivered better results in the past quarter; and a number of countries are formally out of recession. The recovery is still fragile, and in many parts of the world will be slow and progressive. This is as true in our own sector as it is in others. The crisis has served to remind us of some already established dynamics, which perhaps were not given as much attention as required. The most significant of these is the differing dynamics between the developed and the developing economies. I remain cautious about the developed world. But I am optimistic about the developing world—and in particular the BRIC countries—which (are) rebounding more swiftly than many had envisaged. China’s economy has rebounded from a low of 6.1% in the first quarter to 7.9% in the second thanks in a large part to the government’s 4 trillion yuan stimulus package. I don’t have to tell anyone here today that China has an increasingly important role to play in the world. China has the world’s biggest currency reserves, which grew by US$178 billion in the second quarter to a record US$2.13 trillion; it is the largest creditor of the U.S., with an estimated US$776 billion of U.S. treasury bonds; and it is expected to overtake Japan by 2010 as the world’s second largest economy. The latest IMF forecasts output in 2010 will grow by 9% in China; 3.5% in Brazil and 6.4% in India. This trend is not likely to be reversed. The same is true in our industry. When this organisation met earlier this year, it concluded that Chinese demand growth would decline 5% this year where it now seems that demand will actually grow by approximately 15%. This is partly a result
of the government stimulus program and it would be naïve to believe that this level of growth is sustainable. Nevertheless, China and other developing economies have certainly not finished their path of industrial development. Nor, when one looks at the basic fundamentals, are they likely to for some considerable time to come. This is why similarly Indian steel mills are back working at virtually full capacity; and in Brazil, demand is up 40% from its trough. It will be important that this growth is handled responsibly. So whilst it is only natural that countries will want to invest inline with internal growth, they should be mindful of growth for export based on subsidies or involving dumping. It was interesting to read the recent announcement of the Chinese government about the risks of rising overcapacity in the Chinese economy and its subsequent plan to combat overcapacity in seven industries, including steel. The Chinese government wants to consolidate; it wants to shut down more inefficient and environmentally unfriendly producers; and it wants to shift production to coastal sites. The situation in the developed world is less positive, although we do believe that 2009 will be the trough of the cycle. Although many developed economies are now technically out of recession, recovery will be slow and progressive. World Steel’s Short Range Outlook projects growth of 9.2% to 1,206 mmt – equal to the levels of 2008. This includes a 15% improvement in the developed world. But it should not be forgotten this is coming off a 34% fall this year. So demand and therefore production in the developed world will still be significantly down compared with 2008. The steel industry can continue to flourish in the developed world. Demand in these economies may not have the same significant growth potential as the developing economies. Nevertheless the lesson from today is that companies in the developed world must strive to improve productivity on a continual basis. They should also focus heavily on R&D as it is an area which lends itself to further fruitful collaboration between companies in the developed and developing world. It is also crucial in the issue of climate change, an issue becoming increasingly central to government policy. Whilst supportive of the effort to reduce emissions, it will be important to ensure a level playing field and a truly global solution. Ahead of Copenhagen in December, it is very encouraging to see that some new countries including China are also now signing up to cut energy use and carbon intensity. The issue of climate change cannot be solved by the developed world alone. China’s investment in wind and nuclear energy combined with its commitment to reduce energy intensity by 20% between 2006 and 2010 is an example. It’s been a very difficult year, but our industry can actually emerge stronger, provided we learn a few basic lessons. We must focus on cost and productivity and we must become more efficient in the use of the world’s scarce resources. Finally, we must also continue to focus with great dedication to improving health and safety. The current injury frequency rate for our industry is 3.6 per million man hours. This of course is an average, based on all reporting companies. The best performing company, I understand is reporting a frequency rate of 0.8. This shows the enormous improvements that the steel industry still must make in health and safety.
AMSC forms subsidiary in India to support its energy technology
Citing the importance of serving India’s rapidly growing wind energy and power grid markets, U.S.-based American Superconductor Corporation (AMSC) has formed AMSC India, a subsidiary based in Delhi with a service office in Pune to support the company’s power electronics and superconductor-based technology. “India is beginning to tap into its renewable energy resources and is making significant investments to vastly improve the throughput and reliability of its power grid,” said AMSC founder and CEO Greg Yurek. “AMSC India has been formed to provide high-quality local technical support for our new wind power customers and build a strong foundation for future sales into India’s broader renewable energy and power grid markets.” AMSC India will serve India’s rapidly growing wind energy and power grid markets with AMSC’s power electronics and superconductor-based solutions, said a press release that noted the following. According to the World Bank, roughly 40% of residences in India are without electricity, and blackouts are a common occurrence throughout the country’s main cities. To address this shortfall, the Indian government has established an ambitious “Power for All by 2012” plan that will require the country’s installed generation capacity to grow from 140,000 megawatts (MW) to nearly 225,000 MW by 2012. It also will require billions of dollars of investment in India’s transmission and distribution infrastructure. The Global Wind Energy Council’s Global Wind 2008 Report notes that India now ranks fifth in the world in terms of total installed wind power capacity. Capacity in the country grew by 22 percent in 2008 to 9,600 MW. The Indian Wind Energy Association estimates that the country has 65,000 MW of wind power potential. AMSC notes that it has received contracts from two wind turbine manufacturing customers in India, Ghodawat Energy Limited and Inox Wind Limited, both of which have licensed AMSC Windtec™ turbine designs within the past 18 months. AMSC has received initial orders for five wind turbine electrical systems from Ghodawat and three wind turbine electrical systems from Inox.
Latest Nexans deal in India is to supply cables for Mumbai Metro train sets Nexans has been chosen to supply all of the onboard power, control, and data cables for a fleet of 16 trains currently under construction for Phase 1 of the new Metro system in Mumbai, India. Over the next year, Nexans will supply the company with specialized rail cables for installation on 16 four-car Mumbai Metro trains. The cables, part of Nexans’ FLAMEX® range of special cables for the rolling stock industry, will be manufactured to the international NFF standard, and be used to distribute power throughout the new trains. They will also provide control and data communica-
INDUSTRY NEWS tion services for a variety of high-tech ancillary systems such as signaling and passenger information. The contract was awarded by China’s Nanjing SR Puzhen Rail Transport (NPRT). Nexans reports that it has worked closely with NPRT to develop the ideal cable solution for each application. This collaboration will see an important advance in cable technology for Nexans as it will be the first time that it has supplied twisted power cables for a rail customer, the announcement said. The twisted design for the power connection between the converters and traction motors is planned to eliminate harmonics and improve the stability of the traction system as well as meeting EMC requirements.
FLAMEX® multicore cable. The Mumbai Metro train power cables will be manufactured by Nexans (China) Wires & Cables Co. Ltd, while the control and data cables will be produced by Nexans Communications (Shanghai) Cables Co. Ltd. Earlier this year, Nexans bagged another project in India, that one a 15 million euro contract by the Tata Power Company Ltd, India’s largest private sector power utility, to design, manufacture and supply high voltage underground cables to reinforce the power infrastructure in Mumbai, India’s financial capital and the second most populous city in the world. It will deliver five complete circuits of 220 kV cable and associated accessories to provide an extra 300 MVA of power carrying capacity for the underground network linking various Extra High Voltage (EHV) substations across Mumbai. Nexans should supply the cables during 2009 and 2010 to meet Tata Power’s project implementation phases, which will continue until 2011. The Cross-linked polyethylene (XLPE) cable will be manufactured in Nexans plant located in Hannover, Germany while the accessories will be supplied by the Nexans plant of Cossonay in Switzerland.
Sterlite Technologies wins 6th straight award, notes expansion mode continues
For the sixth year in a row, Sterlite Technologies Limited, a leading global provider of transmission solutions, has received the V&D100 2009 award for “Top Telecom Cables Company” in India. The company, which has seen steady growth, also reported that it plans to continue its expansion mode. The annual survey on the Indian telecommunications equipment industry was conducted by Voice & Data Magazine, which notes that the Indian telecom cables market in FY 2008-09 was Rs 1,229 Crores, of which Sterlite had a dominant market share of more than 30%, a press release said.
Sterlite’s contribution to the Indian telecommunications industry, it noted, has been repeatedly recognized through this forum as it is the only company to have won this award for six consecutive years from 2004-09. “Despite the current situation in the global marketplace, several global economies continue to build telecom infrastructures in preparation of economic revival,” said Sterlite Technologies COO K.S. Rao. “Our global footprint extends to several of these economies and we continue to be bullish on the telecom sector.” The company also confirmed its ongoing expansion plans. It noted that work continues at its optical fiber facility to expand its million-km capacity to 12 million km, a goal that had been established. However, “Sterlite has decided to further enhance this capacity to 20 million km, which would position [it] amongst the top three manufacturers globally.” The goal is to attain the additional capacity by 2011. It added that a project is also underway to increase fiber optic cable capacity to 6 million km.
opened a subsidiary in India in 2004. SIKORA INDIA, located in New Delhi, is managed by Mr. Prem Saggu. He and his team support Indian customers with technology and service on site. Familiar with the economic potential of the far eastern markets, SIKORA’s management team has also set up offices in China and Korea and will soon open an additional office in Japan. The offices work in conjunction with local representatives in Indonesia, Malaysia, Philippines, Singapore, Taiwan, Thailand and Vietnam, a company release said.
India and Sri Lanka close to deal for undersea power line Tamil News Network reports that India and Sri Lanka are close to signing an agreement calling for construction of an undersea power line between South India and Thalaimannaar in Sri Lanka. It said that the construction work of the power line, long planned, will start next year and cost an estimated $500 million, according to a Power and Energy Ministry spokesman who said that the cost will be shared by both countries. The power line would provide opportunity for both countries to transmit power in either direction as needed. Approximately 500MW to 1000MW of electricity will be purchased from India under the first and second stage of the project and Sri Lanka is expected to sell its electricity to India from 2018, the spokesman said in the report. He noted that plans call for some 5,400 MW of electricity to be added to the national grid by 2018, at which time the national supply will be more than the requirements of the country. The power projects underway such as Nuraichchoalai, Upper Kotmale, Trincomalee, and Kerawalapitiya will add 900MW, 150MW, 1000MW, 750 MW electricity, respectively, to the national grid. At present electricity capacity in the country is 2400MW and the electricity demand will be increased by 10% yearly, he said.
X-RAY 8000 NXT scanner box.
similar to what is currently being seen in India. As we look at the Chinese market today, there are more than 200 of our X-RAY 8000 measuring devices installed in cable production lines. That shows great promise for the future of the Indian market,” Prunk said. SIKORA’s next generation X-RAY 8000 NXT model measures extremely large cable diameters of 180 mm for Catenary Continuous Vulcanization (CCV) and 220 mm for Vertical Continuous Vulcanization (VVC) lines. The device measures wall thickness, eccentricity, diameter, and ovality with high measurement and repeatability using only one scanning process to calculate all measurement values, a company release said. For more information about SIKORA contact Mr. Prem Saggu at: SIKORA INDIA, 1/36, 1st floor, Mall Road, Tilak Nagar, New Delhi - 110018 India, Tel.: +91-11-4144-7913, Fax: +91-11-45597434, E-mail: sikoraindia@gmail.com.|WB
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“South-east Asia is a market that will further emerge. It is pushed by the dominating markets: India, China, and Korea. Also, Thailand and Vietnam have big market potential and will have a decisive impact on the South-east Asian region,” said SIKORA AG CEO Harry Prunk. “We are now recognizing a similar economic situation in India that we noticed in China 10 years ago. In China the economic upswing of the nationwide electrical power supply started slowly,
SIKORA positioned to meet emerging opportunities in India with measuring and control technology India’s backlog of demand for electrical power supply, particularly in rural households that are not connected to the main supply, has increased governmental investments in power generation. The heightened demand for cables and investment in wire and cable production lines points to significant growth potential for building wires and medium-, high- and extra high-voltage power cable to meet the country’s swift development of production and infrastructure. SIKORA AG, a Bremen/Germany-based manufacturer and worldwide vendor of measuring and control technology, is a supplier to the Indian wire and cable industry. SIKORA-technology is used to ensure online quality control for material efficiency and cost reduction during cable production. As a result of the increasing demand for cables in the Indian market, SIKORA
NOVEMBER 2009 | 5
PEOPLE WAI INDIA CHAPTER HISTORY This new version of the Wire Bulletin coincides with the seventh anniversary of the chartering of the WAI India Chapter. The chapter was officially chartered by the Wire Association International board of directors at Wire Expo 2002 in Chicago, Illinois, USA. The chapter was represented at that event by President R.K. Tyagi of Assomac Group, Vice President Mahesh Astavans, Secretary Nirmal Singh of Assomac Group and Treasurer Harish Jindal of Kay Pee Dies & Tools. 2002 WAI President Scott Higgins said at the time of the chartering, “The creation of the India Chapter continues to enhance the international presence of WAI, as well as help meet the needs of the individuals in the wire and cable industry in a growing India market.” The chapter has been instrumental in WAI’s involvement in India, and has helped extend the educational opportunities available to the industry. The chapter’s leadership held technical symposiums in conjunction with both the 2003 and 2005 Wire & Cable Expo events held in New Delhi. These events gave exposure to the chapter and the WAI, and, as Chapter President Tyagi noted, “we are pleased to offer attendees the opportunity to learn more about the latest technical aspects of wire and cable manufacture. The chapter appreciates the opportunity to work with show organizers to add to the value of this event.” The chapter hosted WAI’s 2006 International Technical Conference (ITC) in New Delhi, which marked the first-ever ITC in Asia. The event provided meaningful educational programming and valuable networking opportunities for those in attendance, as well as an introduction of the WAI Wire & Cable Services Pvt Ltd office in India. Key to the success of the event were Tyagi, Jindal, Singh and Mahesh Poddar of Miki Wire Works and S.J. Kanal of SAI Forge Pvt. Ltd. who added their expertise to the program. The membership in WAI and the WAI India Chapter has grown since the chapter’s inception. Of the 75 current active members, 61 have joined since the chartering of the chapter. And, the membership reflects the industry within India, with representation from the ferrous, nonferrous, and supplier segments of the market. In recent years, the chapter has been supportive of the 2008 technical symposium on “Wires in Automotive Applications” held in Pune at which technical papers were presented and tabletop exhibits displayed products such as fasteners, steel tire cords, springs, electrical cables, harnesses, and more. And, last year, the chapter was present along with the WAI at the Wire & Cable India show in Mumbai, where a number of new members and subscribers to the Wire Journal International and Wire Bulletin were recruited. With more than 1,000 subscribers to Wire Journal International, India now boasts the second largest subscriber base in the world. Additionally, after just two years in publication, Wire Bulletin serves more than 1,500 readers who are part of the Indian wire and cable industry.|WB
Bajaj
Saggu
People on the move STAKU Anlagenbau GmbH has named Nair Indu Kumar as its exclusive sales representative for India, located in Kerala. His career began in 1975 in the aluminum industry as an assistant engineer and he became senior manager for product development and sales in 1995. He has also worked as an R&D engineer in the steel wire industry, where he gained experience manufacturing galvanized wires, PC, spring, and nail wire. Since 1997 he had worked as deputy general manager (technical) for a leading manufacturer of aluminum and alloy conductors. “With this new business cooperation STAKU wants to improve its presence in the Indian wire industry and the service quality to the customers,” the company said. Based in Germany, STAKU Anlagenbau GmbH manufactures wire cleaning and coating equipment for inline and batch treatment. Mr. Punkaj Kumar Bajaj has been named the new managing director of the Steel Authority of India Limited (SAIL), Durgapur Steel Plant (DSP), replacing outgoing managing director, Mr. V. Shyamsundar. His new role became effective November 1, 2009, after a ceremony held at Ispat Bhawan on October 31, 2009.
Before taking over as managing director, SAIL, DSP, Mr. Bajaj was Executive Director, Operations and In-charge, Special Steels at the SAIL Corporate Office. Mr. Bajaj’s prior career with SAIL includes ascending roles in several departments such as production planning and modernisation at the Rourkela Steel Plant (RSP); an assistant general manager’s post at the Bhilai Steel Plant (BSP); leadership in the marketing and strategic planning areas; an executive directorship of project implementation at BSP; and work in the corporate office as the chairman’s secretariat. Mr. Bajaj is well known for his astute planning and coordination skills. His focus on operational efficiency and value-added special steels has influenced the recast of the SAIL’s product offerings resulting in special steels with higher net sales and competitive advantage in a recessionary steel market. Mr. Bajaj studied metallurgical engineering at the University of Rajasthan. Mr. Prem Saggu manages SIKORA’s subsidiary in India. The office, which opened in 2004, is situated in New Delhi. Mr. Saggu and his team support Indian customers with technology and service on site to ensure online quality control for material efficiency and cost reduction during cable production. To learn more about the specialized measuring and control devices for medium-, high-, and extra high-voltage cable available from SIKORA, contact Mr. Saggu at:SIKORA INDIA, 1 /36, 1st floor, Mall Road, Tilak Nagar, New Delhi - 110018, India; Tel.: +91-11-4144-7913; Fax: +91-11-4559-7434; E-mail: sikoraindia@gmail.com.|WB
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6 | WIRE BULLETIN
FEATURED CONCEPTS World’s top management authority calls for radical innovation at first India Business Conference
.K. Prahalad, recently named the world’s leading management authority for the second time, is best known for his work regarding the “fortune at the bottom of the pyramid.” But as Prahalad imagines an India after 75 years of independence, he foresees a new shape on the horizon.
C
The following material is printed with permission as an excerpt from a recent interview with Professor C.K. Prahalad, Ross School of Business, Ann Arbor, Michigan, USA. “I am always accused of having thought about the pyramid,” Prahalad said. “But I was very clear since day one. Our job is to understand the pyramid so it becomes the diamond—so most people live normal, middle class lives. That, I think, should be our goal as managers and people of privilege.”
Prahalad
“Now is the time for imagination, aspiration, disruptive business models.” – C.K. Prahalad –
In order to convert a billion people into the largest economic opportunity the world has ever seen requires the integration of three key elements: economic strength, technology development, and moral leadership. “History has shown that economic strength and vitality of technology without morality is defunct,” he said. “No other country has as much diversity in terms of language, religion, and ethnicity as India. If we can learn to live in harmony and leverage our diversity, we can demonstrate that the world can live in peace. It’s an obligation that diversity is something to be celebrated and leveraged, not squandered.” And it all starts with a goal of 200 million college graduates, a workforce of 500 million trained workers, universal literacy, and 300 new cities by 2022, he said. So far, the goal of 500 million trained, skilled workers is one the Indian government has officially embraced, Prahalad said. And it’s a goal that requires unprecedented innovation. “To train 500 million people at world-class levels and at low cost [in just over a decade] is a goal no society has ever attempted.” Embracing this kind of radical thinking could be one reason that Prahalad has topped CrainerDearlove’s “Thinkers 50” list of the Most Influential Business Thinkers for the second time. In 2007, he also placed No. 1 on the biennial ranking of the Top 50 management thought leaders worldwide. He says it’s time to eschew traditional strategy in order to actualize an India that plays a significant role in shaping the new world order.
“Leadership is about the future,” he said. “We can understand the past, but not be constrained by the past. You cannot start with where we are, and yet that’s what most strategy does. When you start with the current situation you can only extrapolate. Strategy is not about extrapolation. Therefore, I think our job is to imagine the future first and fold the future in.” Training India’s exploding youth population at world-class levels, despite a current dearth of schools, teachers, and resources clearly requires a new approach. “The methodology cannot be business as usual,” he said. “We must have ‘stretch goals.’ There is no way to train 500 million kids in world-class skills using the old ways. The worst thing that happens everywhere in India is that we have no resources. But no entrepreneur starts with resources. They start with aspirations.” India needs to develop a new social compact in which the private sector, public sector, and civil society work together, but never forget their independent roles, he notes. Engagement with India requires excitement, energy, and empowerment. “Those are the operating terms for me that make sense in India.”
“In order to convert a billion people into the largest economic opportunity the world has ever seen requires the integration of three key elements: economic strength, technology development, and moral leadership.” So what are the challenges for CEOs, whether young entrepreneurs or multinational conglomerates? How does one develop new strategic capital and fundamentally new ways to compete? “You have to create disruptive business models,” Prahalad said. “By choice. Ask yourself: Does [this model] radically alter the economics of the industry? Does it improve functionality? Does it make it difficult for incumbents to react? Is it sustainable? And does it enlarge the size of the market?” Cell phones, generic drugs, the Indian auto industry, and even ringtones all illustrate the point, he notes. In fact, telecom services provider Bharti Airtel is now the
“What if we combine in one device the selected functionalities of a PC, a cell phone, and a Kindle, and sell it for $100?” largest music company in India. Its $500 million ringtone business did not even exist five years ago. Advanced technology is required in all of these disruptive business models. “What India needs is the most advanced technology adjusted and adapted to its needs,” Prahalad said. “Technology today is no longer a differentiator between the rich and poor. Everybody can have high-quality technology solutions.” A billion people getting their hands on [hundreds of millions] in new technology is bound to change the way people think, and will radically impact education in India, he says. For example, unlike consumers in advanced economies who have multiple options for electronic devices and information carriers (PC to PlayStation; landline to wireless; cable to satellite), Indian consumers tend to own one device (a cell phone) with a single carrier (wireless). But they still want all the functionality and portability of multiple devices. Innovation is bound to emerge from that desire. “What if we combine in one device the selected functionalities of a PC, a cell phone, and a Kindle, and sell it for $100?” Prahalad said. “What I find fascinating is that Netbook was not invented for the U.S. It was invented for India, but they sold two million Netbooks here last year. This is going to be a very big issue. And I wonder, would you, if you were a young manager at Microsoft or Google or Intel, worry about this issue? I would be extremely concerned.”|WB
Biographical Information Prahalad is the Paul and Ruth McCracken Distinguished University Professor of Strategy at Ross School of Business, Ann Arbor, Michigan, USA. He presented his vision for “India at 75” during the first India Business Conference hosted at the school Oct. 10. The renowned scholar and strategy expert is credited for having coined the term “core competencies” and is the author of the groundbreaking book The Fortune at the Bottom of the Pyramid.
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NOVEMBER 2009 | 7
FEATURED CONCEPTS Goa moves toward eco-friendly infrastructure lanners and architects are working on a plan to use green, eco-friendly, and innovative principles for the infrastructure in the state of Goa.
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The Confederation of Indian Industry (CII, Goa) and Indian Institute of Architects (IIA) Goa chapter are working in unison to promote green buildings, houses, and factory buildings in the area.
In a report in The Times of India, Dean D’Cruz, an architect and former IIA chapter chairman said, “We are working on the building design, incorporating the green concept and doing computer test models to ensure that the buildings are really energysaving before we actually build them.”
CII-Sohrabji Godrej Green Business Centre. The Indian Green Building Council (IGBC) encourages promoters of green buildings so that they are accessible to the
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public. A video on green buildings was released this year at the Green Building Congress which is available for download at the IGBC website. The video shows the numerous types of green building projects in India and references the local chapters within Indian cities.
“We are working on the building design, incorporating the green concept and doing computer test models to ensure that the buildings are really energy-saving before we actually build them.” – Dean D’Cruz –
The group’s research shows that conventional buildings consume 40% of the energy used on earth. Realizing the green building concepts may mean energy savings of between 30-40% and water savings in the range of 20-30% depending on the type of structure, which is of interest to India’s fast growing construction sector. For individuals building homes, this green initiative would mean support from the Confederation of Indian Industry (CII). CII will provide contacts to manufacturers of environmentally friendly material and guidelines for green construction.
The IGBC is also getting involved with a rating program for both green homes and factory buildings. Green ratings from IGBC, similar to the effects of ISO certification, can help hotels and commercial housing ventures. Ratings are not needed for private residences, however green principles during construction can help toward the initiative. By design green buildings use less water, are energy efficient, conserve natural resources, and reduce waste, which results in healthier spaces than conventional buildings. D’Cruz explains, “Green buildings use less energy, and initially cost 5% to 7% more because users are paying for new systems and research and development costs, but within five years, they can recover the costs and start saving.”
“Green buildings use less energy, and initially cost 5% to 7% more because users are paying for new systems and research and development costs, but within five years, they can recover the costs and start saving.” – Dean D’Cruz –
For more information visit The India Green Building Council website at: http://www.igbc.in.|WB
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NOVEMBER 2009 | 9
PRODUCTION TIPS Excerpt from: Theories of Die Design Thomas H. Maxwell Sr. Die Quip Corporation www.diequip.com Today’s wiredrawing techniques feature some updated production methods that provide better quality at lower costs. The increased use of mechanical descaling and higher drawing speeds have raised demands on the wire mill and carbide dies; accordingly, changes have been necessary to update descaling, lubrication, and die profile specifications to achieve optimum machine performance and operating costs. These changes call for a better understanding of how die geometry and finishing techniques can be used to gain more consistent die performance, longer life, better lubrication, and lower temperatures. This excerpt is intended to illustrate the significant role of the approach angle to the wiredrawing process.
The approach angle has three major functions, which must be considered when selecting the correct angle for each application. 1. The approach angle lubricates the surface of the wire prior to reduction by producing pressure, which promotes hydrodynamic lubricant flow. 2. The reduction zone is where the die reduces the diameter of the incoming wire. This reduction causes plastic flow of the material changing its physical properties by imparting a dense metallurgical structure, hard surface, and improved finish. 3. The approach angle also sizes the material at the point it meets the bearing intersection. The bearing only controls size. It does not generate the wire diameter.
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When the approach angle is too narrow or the reduction in area is larger than the angle can handle, the wire can come into contact with the die as it enters near the top of the die angle.
Selecting the correct die angle
Approach angle The approach angle is the most important section of a wiredrawing die. The entire reduction in area and the compacting of lubricant onto the incoming wire surface occurs in the approach angle. Die efficiency is determined by the design and accuracy of this approach area, which must be cut to an accurate conical angle with a smooth surface finish. It must be straight sided without a distinct radius or blended contour along its entire surface. The angle must be precision machined to ensure the angle and bearing surfaces have a common centerline. In addition, these surfaces must be concentric with the outside diameter of the steel case to prevent out-of-round wire.
double angle die can also be used to design a die to accept both heavy and light drafts with the first angle handling the heavy reduction while the second angle eases the transition for the heavy draft and can successfully draw the light reduction.
The sizing of the material can be affected by an approach angle that is too wide because as the material flows down the angle it has a more severe transition to the bearing causing the material to cave undersize. When the draft is too light the wire contacts the approach angle so close to the angle/bearing intersection that any misalignment or wire movement causes the material to skip over the intersection resulting in chatter marks or inconsistent diameters. The following results can be expected when an approach angle is too wide or a reduction in area is too light.
The only way to select an approach angle is by the reduction in area that will be taken by a particular die. If you did this for every draft you would have so many different approach angles that it would be a logistic nightmare. Fortunately, there is a range you can use that is based on the contact point between the approach angle and the incoming wire. A good contact point is 72 to 100 percent of the bearing diameter from the intersection of the approach angle and bearing. A final problem associated with the approach angle is draw down, which is a phenomenon in which the material reduces to a smaller diameter than the die size. This can result from an angle that is too wide, from excessive die pull, or from material that has low tensile strength. Draw down makes it difficult to maintain size and control roundness but it can be solved by easing the transition between the approach angle and bearing. The simplest and most accurate way to ease the transition is to add a second angle which is half of the approach angle and approximately .032" to .187" long. The
Summary If you do not take the time to review die angles in relationship to reduction in area it will be very difficult to produce quality wire, test items such as different lubricants or rod sources or produce wire at promised drawing speeds from machinery builders. Also, if you do not understand the effect the die has on wiredrawing it will be nearly impossible to effectively solve problems because every part of the drawing process has variables that would need identification. In conclusion, the wire die is vital to the efficiency, quality and profitability of your wire mill.|WB
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PRODUCTS, MEDIA, & TECHNOLOGY Products
Slickline wire offers longer life
Company to offer equipment with new high-convection annealing technology
Sweden’s Sandvik Materials Technology reports that it has introduced a range of bright-finish slicklines that it said offers significant benefits over traditional matte surface lines.
SECO/WARWICK USA (SW) reports that via its 50-50 joint venture with India’s SECO WARWICK Allied Pvt. Ltd. (SWA), it will offer H2-HC (high-convection) hydrogen bell annealing and steel reheat furnaces in North America. A press release said that SWA has been designing and manufacturing equipment for the steel industry since 1971, and that its technology will be adapted for the NAFTA region. The manufacturing will be done at SW’s 110,000 sq. ft. facility in the U.S. SWA, it said, has supplied more than 200 H2 annealing bases, with capacities up to 120 metric tons.
The release noted the following: the H2HC system may be used for both wide and narrow width coils using cracked NH3/H2 gas as a protective atmosphere. The system uses high convection heat transfer with hydraulic clamping and mechanical locks for safe operation. Dehumidification and coil cooling and storage systems are available. High convection heat transfer provides optimum temperature uniformity, which, in turn, produces a higher quality crystalline structure, reduced decarburization and homogeneous physical properties of the annealed material. Contact: SECO/WARWICK USA, Tel.: (001) 814-332-8400, info@secowarwick.com, www.secowarwick.com.
Also known as wirelines, the slicklines are single strands of metal wire used by operators of oil and gas wells to lower heavy tools and equipment into a well. A press release said that the Sandvick slicklines offer greater life expectancy than traditional matte finish lines, with tests showing that the product provides more than 15% better fatigue resistance. That, it noted, means there will be fewer line replacements, which reduces operational costs. It added that the lower friction rate of the brightsurface slickline also means longer life expectancy for pulleys, sheaves and counters. It added that the slicklines can reduce friction in the stuffing box, preventing a troubling “wire wool” condition. The release notes that the company’s wirelines traditionally have high corrosionresistance, high mechanical strength and uniform tensile properties, but due to the nature and type of slickline applications, even alloy lines can become susceptible to corrosive attack. “These new bright finish slicklines, with their smooth surfaces, significantly reduce microscopic pores that can lead to pitting, especially on the section of the line exposed to the aggressive conditions encountered in the deepest part of a well,” it said. Contact: Sandvik Materials Technology, Tel.: 46-26-26-30-00, www.smt.sandvik.com/wire.
PROFILEMASTER® PMM 80 measures cable, tube profiles
Media
Zumbach Electronics introduces a new, compact profile measuring system for cables made of plastic, rubber, metal, steel and other materials, as well as tubes. The PROFILEMASTER® PMM 80, the latest model available in Zumbach’s PROFILEMASTER family, enables measurement using the Light Section principle and Machine Vision. A release details the system’s benefits such as increased accuracy; improved process control; scrap reduction; raw material and post processing savings; ease of installation on existing production lines; and seamless integration of the PCbased system.
Siemon’s report covers video over structured cabling network
Contact: Zumbach Electronics Corp., Tel.: +1 914-241-7080/303 or visit www.zumbach.com
According to the report, increasing numbers of building owners choose to support broadcast, surveillance, and video applications with their telecommunications cabling infrastructure because of the enhanced capabilities of “smarter” video applications. The result is that generic coaxial cable can no longer adequately support these applications. One example provided in the report covers broadband video applications and signals, which are best transmitted over twisted pair cables. It presents a cable-sharing capability in which both analog and digital video and audio can be transmitted over one pair of a twisted pair cable. Figures present video and distribution topology, and the typical distances supported by the category 7A cabling are presented in table format. The 14-page white paper provides a comprehensive overview of key video applications and guidance on implementing a suitable cabling infrastructure. Electronic copies of the Siemon’s report are available at the Siemon’s website: www.siemon.com.
continued from p. 1
Q:
What calculation is needed, if any, for the proper percentage between dies?
A:
The relation of the % Reduction of Area with the diameters of the capstans is: %RA=100%-(Bottom Capstan Diameter x100)/Top Capstan Diameter
Q: How many feet of cable can a reel hold? A: First we need to calculate the
constant “C” C = π/12D2 where: π = 3.1416 D = Diameter of cable (inches) Example: a cable with 1/8" (3.175 mm) diameter is 0.125" C = (3.1416/12 x (.125)2) = 16.755
Raajratna capabilities brochure available online M
P
S
Formula = (M + P) x S x M x C Example: To get how many feet of cable of 1/8" (3.175 mm) feet in a 1000 mm flange x 500 mm drum x 630 mm traverse reel. First, we need to convert to inches: Flange = 1000 mm = 39.370" P = Drum = 500 mm = 19.685" S = Traverse = 630 mm = 24.803" M = (Flange – P)/2 = 250 mm = 9.842" C = 16.755 (already calculated)
A 26-page capabilities brochure from Raajratna Metal Industries Limited, an ISO 9001:2000 accredited stainless steel wire manufacturer, is available for viewing and download from the company’s website. The brochure mentions the company’s use of 100% green power to manufacture its line of industrial stainless steel wires, stainless steel bright bars and spring wire, nail wire, stainless steel welding wire, and cold heading wires and it details those product types with specifications presented in data-sheet style. Chemical compositions are also presented in detail. Applications for the company’s products include conveyor belts, nails, kitchenware and baskets, braiding hoses, screens, chains, and wire ropes among others. Contact: Raajratna Metal Industries Limited Corporate Office, Tel.: +91-79-2754 3681/82/ 83/84, or visit www.raajratna.com.
Data sheet details nickel plated Dumet wire “Getting the Picture: The Benefits of Supporting Video Applications with your IT Infrastructure,” is the title of Siemon’s newly published technical whitepaper by cabling expert Valerie Maguire. Described as a paper “written to help network professionals select a structured cabling network capable of supporting the widest array of enterprise-level video applications,” the document describes the need for, and performance capabilities of, such structured telecommunications cabling networks.
ASK THE EXPERT
JLC Electromet Pvt. Ltd., Jaipur, manufactures wire, strip, and ribbon using nickel and nickel-based specialty alloys. A data sheet about the company’s Dumet wire products, which consist of nickel-iron core in an oxygen-free-high-conductivity sheath, is available for viewing and download from the company website. The company offers copper-clad Ni-Fe wire; Dumet with FENI 42 core; and copper-clad 24 and 26 wire. Additionally available Dumet wire grades include borated, oxidized, and bare.
Formula = (M + P) x S x M x C = (9.842 + 19.685) x 24.803 x 9.842 x 16.755 = 120,768 feet
Other product lines include welding rod core wire and clad wires. The organization is an ISO 9001:2000 company that supplies more than 40 countries and was awarded the Philips Global Supplier award in 2008.
Contact: JLC Electromet Pvt. Ltd., jlc@jlcelectromet.com; Tel.: +91 141 233 0375 or download the data sheet at www.jlcelectromet.com|WB
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NOVEMBER 2009 | 11
TECHNICAL ARTICLE Use of Color-changing Pigment to Detect Wire and Cable Hazards This technology represents an opportunity for forward-looking wire and cable manufacturers to provide and market new cables that meet the increasing demand for safer products. By Walt Ogrodnik
This paper presents the latest technology of color-changing thermochromic substances for wire and cable professionals, focusing on thermochromic applications to the insulation/jacketing of electrical conductors (including plugs) to detect thermal hazards. Thermochromics are poised to transcend their prior novelty and food temperature applications by providing an efficacious, high-value, low-cost substance for innovative color-changing wire and cable safety uses. The paper begins with a brief scientific description of various classifications of “Chromism,” including the two most common types of chemical colorants used in thermochromic color applications today. One colorant, in particular, is the focus of this paper, i.e. color-changing Leuco Dyes (LD). The paper also addresses some of the principles and more common conditions leading to hazardous conductor over-heating; some statistics about damage caused by undetected wire and cable faults; best practices for the extrusion/injection process; and non-extruded/injected LD applications. Finally, for an industry constantly competing with price-sensitive generic wire and cable commodities, there is a detailed model of the typical financial costs and expected returns, along with a market survey summary on consumer pricing and preference.
The science of chromism Chromism is a process that induces a change (typically reversible, yet, it can be irreversible) in the colors of certain compounds. In most situations the change is based on external stimuli which, in effect, transfers energy and alters the density of the electron state of the molecules. It is the absorption of this energy and subsequent reflection of light in different wavelengths that causes a color change. There are many artificially synthesized, as well as natural, compounds that exhibit chromism. Specific classes of chromism are generally divided by the external stimuli required to induce or create the change. The most common chromism classes today are: Thermochromism, which is induced by temperature (the focus of this paper); Photochromism, is induced by light irradiation; Electrochromism, which is induced by the gain or loss of electrons; Solvatochromism, which is induced by the polarity of solvents; Ionochromism, which is induced by an exchange of ions; Piezochromism, which is induced by mechanical pressure; Tribochromism, which is induced by mechanical friction; and Hydrochromism, which is induced by a change in moisture. Examples of chromism include liquid crystal and LED display screens, films, Transition® eyeglasses, Hot Wheels® toy cars, thermal print paper, carbonless paper, aquarium thermometers, Energizer® and Duracell® battery testers, etc.
Principles of Thermochromism Materials that undergo temperatureinduced color changes are said to be thermochromic. See Fig. 1. The two major
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types of thermochromic material most used for commercial purposes today are Liquid Crystals (LC) and Leuco Dyes (LD).
Fig. 1. Principle of Thermochromism. Liquid Crystals (LC). These crystals (of the thermochromic cholesteric type) possess both liquid (flow) and optically solid (anisotropic) properties. They are very sensitive to temperature in that, thermal expansion (within a narrow range) results in a change in spacing, pitch and layering, hence, discernable reflection of changing wavelengths of light from their structures. LC can be modified in their composition to respond to very specific temperature ranges although color density and color choice is very limited. Because of the inherent sensitivity of LCs, they are used in many applications where very precise readings of temperature are required, such as children’s forehead thermometers, vaccine vials and even mood ring jewelry. The most common method of applying LCs is by inking them on to a substrate. While LCs are very temperature sensitive, they are neither inexpensive nor easy to process or apply. Hence, LCs are typically used in limited applications of higher value and in smaller quantities. Leuco Dyes (LD). These dyes are the other and most common of all thermochromic material in commercial use today. Three major components makeup most LDs including; the leuco dye, a weak acid and a solvent. LDs work because of a temperature induced change in the solid form of the material. As the material gently melts, the pH inside the LDs shell lowers and the LD becomes protonated, consequently shifting its color absorption dramatically. LDs are unique in that they are normally colored in their cool state and, when temperature activated, they transform to a colorless (actually translucent) state. This property allows for many color combinations (cold and hot) when the “clearing temperature” (i.e., the temperature when the material becomes colorless) of the LD is reached. Since the opaque/cold LD becomes colorless when heated, the LD allows the underlying or “hot” color to be visible. LDs are able to be creatively combined with other LDs of different clearing temperatures (and color opacities) to create sequential and near animated changes at increasing clearing temperatures and with different colors. The current range of clearing temperatures can be as low as -10°C to as much as 70°C+ and can be fabricated in almost any color. Unlike the LCs, the LDs have very robust color possibilities. They are relatively inex-
pensive and substantially easier to process and apply. However, LDs are not nearly as accurate at changing color at a precise temperature when compared to LCs. Typically, color will begin to change over a 2-5°C range although certain LDs have been processed to have more or less of a range. Further, LDs exhibit a unique and desirable property for the wire and cable industry called “Hysteresis.” This property, which is defined as a lag or delay in response to the change of stimuli (in this case it is the returning temperature decrease), causes the return color change to maintain its colorless state until it cools 2-5°C below the temperature at which it originally “cleared” during the warming process. The desired range of hysteresis is another variable that can be customized by the encapsulation processor. See Fig. 2.
process and material of the shell and the resultant quality and thickness are primarily responsible for dictating the temperature responses, including the previously explained hysteresis phenomenon. Some microencapsulators claim to have nearly eliminated hysteresis in their LD material. The process of microencapsulation is complex and critical to the quality of the thermochromic material and end application. Better microencapsulating labs incorporate many important factors and additives in their end product such as, particle size, shell thickness, thermal stability, impermeability, shear strength, and compatibility with the surrounding material to be used. UV additives can also be processed into one of the shell layers. It is therefore critical to identify a LD supplier that will listen and compound to the functional needs of wire and cable manufacturing.
Fig. 3. Microencapsulation photo. Fig. 2. Hysteresis of Leuco Dyes. Most LDs used today are reversible. However, LDs can be fabricated to change colors only once when a certain pre-selected temperature is reached. This one-time change involves using stronger acids within the microencapsulation shell that effectively arrest any further electron exchange. While polymerized LDs are used for injection and extruding, they can also be used on as a topical color-changing ink on wire and cable that can be contact printed in wheel-printing, embossing, and hot foil applications; used for pattern printing (e.g., banding, hash marks, spiral or longitudinal striping); or for verbiage or numerals. LDs can be used effectively on adhesive wrap-around labels for retro-fitting existing conductors. This type of LD application (which can be made UV/weather tolerant) is often irreversible or historical. Irreversible color-change labels are often applied to wire and cable since the label can have multiple temperature settings (including high temperature settings exceeding 150°C+) and can be replaced if required. Hidden wiring and/or “warranty voiding” is also a practical application for such labels.
Microencapsulation of Leuco Dyes Leuco Dyes (and liquid crystals) must be microencapsulated before use. See Fig. 3. Microencapsulation of the organic dyes adds stability, color, temperature control and protection of the coloring agents from the environment. In this process, the small particles of color-changing pigment (called the “core material”) are carefully coated with a shell. An interfacial polymerization process is used to form the shell around the dye and solvent. The microencapsulation
A world of color and patterns LDs come in virtually every color in both cold and hot form. LDs lose their color when they reach their “clearing temperature.” When properly mixed with a clear polymer, the plastic should be opaque when cold and nearly clear when hot. See Fig. 4. LDs can be combined with other pigments to affect both the cold color and the resulting hot color. For example a “blue to clear” LD combined with a generic 1-3% yellow colorant will take on a green cold look (blue + yellow = green). When the LD heats up and “clears,” the visible hot color becomes the yellow underlying color. In all combinations, the cold color needs to be a darker color than the lighter hot color.
Fig. 4. Color-changing cable prototypes. Even more interesting and complex than the above is the ability of LDs to be combined with two or more LDs with different clearing temperatures in the same plastic. One example would be to start with the above [green (cold)] to have a color change at 105°F (to warm yellow) while a second color change (using the same or different coloration) could take place at 115°F (say continued on p. 14
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TECHNICAL ARTICLE to hot clear). (If no hot color is used, then by default the hot color becomes the color of the polymer used.) In effect, one can produce a double (or triple) animated sequence of color change over predetermined temperature ranges. Finally, it should be noted that while color to color (-less) change is the heart of LDs, the creative use of patterns that appear or disappear can become a powerful alerting mechanism in itself or for those who are colorblind or visually challenged. One example is the use of striping. The striping effect can also be applied as an “inked” spiral stripe, albeit the stripe would be more prone to abrasive and strong solvent effects. As in the examples above, consider a spiral blended (not visibly noticeable) onto the surface of the wire and cable, as the underlying color disappears the ink spiral now (as a “candy-cane” pattern) is contrastingly very noticeable.
Principles of wire and cable overheating The carrying capacity of a conductor is commonly defined as the amperage it may safely handle. See Table 1. Theoretically, the amount of current that can pass through a single bare copper conductor is limited by the melting point of the bare copper (i.e., 1980°F). However, the polyolefin or PVC insulation/jacketing on most wires and cables will begin to melt at about one-tenth of that temperature. Electric current passing through a conductor always incurs some resistance resulting in heat. Under normal conditions where the conductor is sufficiently sized and properly wired, the heat produced by resistance is not problematic. However, when multiple wires are bunched in a confined conduit, for example, the cumulative heat can lead to hazardous over-heating conditions.
The case for a color-change alert While advances in circuit interrupters (including GFCI, AFCI, wire and cartridgetype fuses, etc.) working on combinations of heat and electrical current have had a mitigating effect on faulty electric circuits, such devices have their limitations and drawbacks. The biggest problem is the expense to purchase and install such devices. Further, there is the issue of whether the device is properly sized and working for the potentially changing conditions. Many such devices have failed over time. Also most devices are either “On or Off” basis and lack a way to show an escalating condition. In large commercial/industrial wiring systems, where wire and cable are visible, infrared cameras are now being used to monitor overheating conductors. Maintenance, Repair and Operation (MRO) personnel understand the associated costs with circuit shut-downs and that many such malfunctions are due to slowly aggravated chronic conditions. Households with numerous extensions cords also understand the safety and fire prevention benefits of an alerting color-changing cord. Several influential regulatory agencies have expressed interest in further development of the colorchanging wire and cable. Another consideration and potential advantage/disadvantage in the use of LD on wire and cable (since it can inadvertently give a false electrical alert), is that all LDs will change colors regardless of the source of heat. This means that wire and cable will change colors when it is exposed to the convection heat of a hot space heater or other
hot appliance, or even if it has been placed near or on a very hot surface, such as an automotive engine. By having a pre-alerting system, a user can see when conductor conditions progressively deteriorate. With such visual alerts, the user may be able to circumvent costly circuit shut-downs, prevent more extensive damage to load devices, lower maintenance and repair cost, and perhaps most importantly, mitigate the extensive risk to human lives.
LD suppliers Few U.S. based companies supply microencapsulated LD material for plastics (see references). The original processing was developed and patented by the Matsui Shikiso Chemical Co., Ltd., of Japan in the late 1980s. When the original patent expired in early 2000, several companies began R&D to microencapsulate LDs using proprietary processing methods and materials. Most but not all U.S. suppliers obtain their encapsulated LD material already prepared from sources in Japan, Taiwan, England, and France.
Best production practices and lessons Based on numerous wire and cable prototyping experiences of the author’s company (see Fig. 4), the following production methods have been established. It is noted that variations among LD material/suppliers, polymer types, processing methods, equipment and even colors will have an effect on individual end results. Some whiteners such as TiO2 will visually block the LD color intensity and should be avoided. CaCO3 and other fillers may also effect the final LD color intensity, but not the the dominating affect of whiteners. LD material is slightly ‘hygroscopic’ and is best kept in dry storage and pre-dried before actual use. LD material can withstand processing temperatures of approximately 450°F+. Processors can exceed this temperature slightly and momentarily if done when shear force or stress on the LD is light. Excessive heat, shear, or mixing should be avoided with certain solvents as they may harm the LD encapsulation. Most LD provided in concentrated masterbatch form will only contain from 10-20% actual pigment. Powdered concentrate LD is also available and contains nearly 100% pigment. Certain LD suppliers provide their LD masterbatch in end-use polymer matches (i.e., PE, PVC, PP, etc.), while others use EVA as a ‘Universal’ base polymer resin. Dilutions of the concentrated masterbatch are typically around 1:10 but depend on the thickness (~30-40 mil) of the insulation/ jacket and the diluting polymer’s ingredients. It has been shown that the clearer the diluting material the better the opacity of the LD and the less LD material is needed. Thicker extrusions require less material than thinner extrusions (i.e., most plugs would be very opaque using a 1:20 dilution or less if using a clear polymer base). Using concentrated LD powder translates to approximately the same total percent of pigment use as other colorants, i.e., approximately 1-3% loadings. All LDs are sensitive to UV radiation. However, irreversible LD can be made UV tolerant. Certain colors fade more easily with UV. While certain UV inhibitors, stabilizers and other additives can be added, more R&D is required to produce an ac-
ceptable long term outdoor grade. One commercial LD encapsulator incorporated UV protection in its outdoor LD products which are currently being used on bridge surfaces to alert drivers to freezing temperatures. Until more UV protection is perfected, wire and cable produced with LDs should be used away from strong UV light.
Summary and future The first-generation of color-changing wire and cable and plugs has already been prototyped and initially tested. Preliminary analysis indicates the samples fall within regulatory compliance tests for the wire and cable industry. All compounded LD material being used is believed to meet RoHS standards, as well. Currently, several “preferred compounders” are devoting additional R&D effort to “best formulating” the plastics to ensure the masterbatch pelletized concentrate and/or “ready to use” forms are commercially feasible for specific targeted markets. These same compounders may soon be approaching wire and cable manufacturers to ensure such “best formulas” and specific cold/hot colors and “clearing temperatures” have been standardized for orderly market introduction and acceptance. Despite the remaining fine tuning of LD compounding before eventual commercialization and licensing to the wire and cable market, the biggest hurdle to wide-spread introduction is expected to be the industry itself. The wire and cable industry is, in general, a mature commodity producer under intense pressure to reduce costs and to compete with off-shore producers. LDs will add incrementally to the unit cost of production and like any new innovation there may still be a perceived risk/cost which only a few selective wire and cable manufacturers (more visionary and early adopters) will be able to justify. Optimistically, LD costs are minimal compared to the potential profit margin and market share gains for both the wire and cable manufacturer and the compounder. Perhaps most importantly and more difficult to quantify, the color-changing wire and cable user should experience a reduction in property damage and maintenance costs, with a priceless improvement in the safety to human life.
nies and organizations who generously reviewed this paper, supplied information and/or were referenced in this paper. Leuco Dye Suppliers: Chuck Boyce, Managing Director, Matsui Int’l Co., www.matsui-color.com; Tim Homola, President, Color Change Corp., www.colorchange.com; Scott Szafraniec, Sales Manager, Liquid Crystal Resources, LLC, www.lcr.usa.com; Doug Koerner, Business Manager, Keystone Aniline Corporation, www.dyes.com; and Yves Ortais, President, Gem’innov Societe, www.geminnov.fr. Prototyping Manufacturers: Grant Campbell, vice president, Multi/Cable Corporation, www. multicable.com. R&D and Test Equipment: Jonathan Meckley, Assistant Professor, Penn State University, Plastics Engineering Technology, The Behrend College; and Alan J. Cortazzo, Custom Test Equipment; cortazzoa@bellsouth.net. Other: Consumer Product Safety Commission, www.cpsc.gov, and National Fire Protection Association, www.nfpa.org.|WB
Biographical Information
Ogrodnik Walt Ogrodnik is the CEO of HazardGuard Safety Wire, Inc., Pittsburgh, Pennsylvania, USA. He worked for 17 years as the Sr. VP/COO of a professional systems integration company in Pittsburgh. His prior work experience included eight years in international development with the U.S. Foreign Service. He holds a master’s degree in economics from Texas A&M University and an undergraduate degree from Pennsylvania State University. This paper, which was presented at WAI’s 77th Annual Convention, Cleveland, Ohio, USA, June 2007, won the Urbain J.H. Malo Memorial Medal Award for best electrical paper.
Acknowledgments and references The author wishes to acknowledge and thank the following professionals, compaElectrical Carrying Capacity of Single Copper Conductors (Using Various AWG and Insulation Types in 30C Ambient Temp.) Polyethylene Neoprene Conductor Polyurethane Polyvinychloride Size (Semi-Rigid) At 80°C 30 AWG 28 AWG 26 AWG 24 AWG 22 AWG 20 AWG 18 AWG 16 AWG 14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG 2 AWG
2 3 4 6 8 10 15 19 27 36 47 65 95 95 125
Polypropylene Polyethylene (High Density) At 90°C
Polyvinychloride PVC (Irradiated) Nylon At 105°C
3 4 5 7 9 12 17 22 30 40 55 70 100 135 180
3 4 5 7 10 13 18 24 33 45 58 75 105 145 200
Table 1. Carrying capacity of copper wire, in amps.
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PERSPECTIVE A D V E R T O R I A L
Enlarged Rosendahl crosshead series Rosendahl has been developing extrusion machinery for wire and cable applications for nearly 50 years. Highly skilled and experienced staff in design engineering, process engineering, and manufacture has now enlarged the product range. The Rosendahl crosshead series serves the needs and requirements of different types of cables that fit every extrusion line. The enlarged series comprises different crossheads for cables up to 110 mm in core diameter for different application areas.
New technology in distributor design The challenge in distributor design is to find the optimum dimensions of the distributor to attain the balanced flow at the exit. Rosendahl’s distributor concept guarantees homogeneous material flow—independent of the processed materials and independent of the output. This optimized material flow provides high centricity enabling a reduction in average wall thickness and, subsequently, reduced manufacturing costs. With the help of the newest finite element simulation programs Rosendahl is able to conduct mechanical calculations and rheological analyses of the crosshead series.
The simulation also enables pressure, temperature rise, velocity, stress and strain rate distributions to be calculated over the entire simulation domain. Especially when designing the distributor, it is important to adapt the distributor’s channels to the flow path of the melt. In order to offer a broad material spectra, Rosendahl researched with university institutes on a wide range of materials for the cable industry and now offers a material database that includes standard as well as special material (foamed material blends, LSOH, XLPE, etc.). Rosendahl’s continuous communication with known polymer manufacturers guarantees up-to-date technology. Rosendahl, as a supplier of extruders, crossheads and of complete extrusion lines, is in the position to investigate and understand the overall polymer extrusion process. The integrated simulation results with the experiential data enabled Rosendahl to optimize the head design and ultimately to achieve perfect quality of the extrudate. Rosendahl is offering the global wire and cable market a full range of premium solutions for customized lines or single machines for the production of power and automotive cables; fiber optic cables; coaxial and LAN cables. Continuous technological development led to the manufacture and production of Rosendahl crossheads.
FOC-Dry tube production RL-R/OFC40 clenching concept Clenching Caterpillar NCA 210 Totally dry cable designs are offering benefits in terms of cable preparation time and fiber splicing costs, respectively.
In conventional cable designs jelly is used to achieve water tightness. In dry tube cable designs jelly can be replaced by swelling materials like super absorbent powders (SAP). An important process parameter in the buffering process is to control the Excess Fiber Length (EFL). The replacement of jelly filling with SAP results in an EFL increase. The invention of the so-called clenching process within the newest generation of high speed “Loose Tube - Secondary Coating Line RL-R/OFC40” buffering lines supports precise EFL control even on small product dimensions. The clenching concept compensates for the EFL increase since low EFL is required for the production of compact dry loose tube Fibre Optic Cable (FOC) designs. A clenching caterpillar, installed in front of the mid-span capstan inside the tube cooling section, ensures a very low tube tension during the tube crystallization process. This also results in less post shrinkage of the produced buffered tube. The clenching caterpillar NCA 210 (see picture), as one important part of the clenching concept, has to meet specific demands related to long-term stability within a challenging environment. Recently carried out design improvements ensure a long-term reliability of the production process. The clenching caterpillar NCA 210 is also suitable for the upgrade of existing Nextrom OFC40 & Rosendahl RL-R buffering lines. The production of loose tubes without jelly filling can cause tube diameter variations and collapse of the tube after the extrusion head. To obtain a uniform tube dimension the diameter of the tube is controlled by the injection of pressurized gas into the tube. To avoid friction between op-
tical fibers and the plastic tube a tube lubricant can be added. Water tightness of the tube is achieved by using super absorbent powders either in the form of swellable powder or in the form of yarns.
Clenching Caterpillar NCA 210. The key characteristics of the patented clenching concept can be summarized as follows: • Integrated EFL process control system for both jelly filled and dry buffered tubes • Tube diameter control system • Specific clenching caterpillar design to cover demanding surrounding conditions • Modular concept, also suitable for the upgrade of existing buffering lines. Nextrom & Rosendahl are global suppliers offering a comprehensive range of highend cable manufacturing systems that are suitable for the production of optical fibers (OF) and fiber optical cable (FOC); telephone; LAN; coaxial; radio frequency; automotive; and power cables and crossheads. Contact: www.rosedahlaustria.com.|WB
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CLASSIFIED & AD SHOWCASE
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