MANUFACTURING PEOCESS IN INDUSTRY-1

MANUFACTURING PEOCESS IN INDUSTRY-2

Curing processes-ISTEAM CURING PROCESS WITH CCV LINE :

This is wet curing process. Cross linking takes place on CCV line under high temperature steam at 200oC and at high pressure in the range of 18-20 bars. During cross linking process the high percentage of moisture is absorbed by the XLPE insulation. By passage of time some percentage of moisture dries out from the XLPE insulation but still it leaves behind moisture in the XLPE insulation 2000 PPM and number of voids in the insulation. The moisture and voids present in the XLPE insulation result in formations of water trees in the XLPE insulation when cables are energized. These trees are converted into electrical trees which ultimately results in shortening the life of the cable and insulation failure. This technology is now out dated and not used.

Curing processes-II

DRY CURING PROCESS

The cable is extruded by triple extrusion in one process on CCV line where Cross linking takes place simultaneously in the atmosphere of Nitrogen gas of high temperature at about 300oC-350oC and high pressure in the range 10-15 bar of dry Nitrogen gas. Since cross linking take place under Dry atmosphere, this process is known as dry curing process.

Major advantage of Dry Curing with Nitrogen Gas are: i) Moisture content in the XLPE insulation practically negligible -50PPM ii) Formation of Micro voids in the insulation almost eliminated.

Global Energy Consulting Engineers, Hyderabad

Curing processes-III

SIOPLAS TECHNOLOGY Saline grafted polyethylene is extruded on normal PVC extruders and after that it is cured/ cross linked by hot water or steam separately.

COMPARISON BETWEEN OHS & UGCS

DESCRIPTION OF CONSTRUCTIONAL FEATURES -1

ConductorCopper / AluminumSolid / StrandedCircular / Shaped / Segmental Ns=1+3n(n+1) and D=(1+2n)d andA = D2 / 4 ; where 'Ns' is Number of strands in the core, 'n' is the number of layers, 'D' is the overall dia of the core and 'd' is the diameter of each strand. Normally the number of strands are 1,7,19,37 and 61. Conductor ScreenSemi conducting screen over the conductor is to prevent discharge between the conductor and the insulation and also to provide protrusion free surface over the core for extrusion of insulation Insulation The materials used for insulation should have Good Insulation Resistance Good Thermal Resistance Non Hygroscopic Good Mechanical properties Good chemical / Alkaline resistant Properties

COMPARISON BETWEEN OHS & UGCS

DESCRIPTION OF CONSTRUCTIONAL FEATURES -2

Insulation Materials Used Rubber Paper PVC XLPE ( Cross Linked Polyethylene )Insulation Screen and Metallic ScreenTo discharge the tangential stress to the ground and to make the stress only radial to prevent damage to the insulationFillersTo fill the gap between the inter-sticks of the cores and to make the shape circularMetallic Sheath / PVC Inner SheathTo make the cable non hygroscopic in the case of paper insulated cables and to bind all the cores together to make the shape circular in other types of cables

COMPARISON BETWEEN OHS & UGCS

DESCRIPTION OF CONSTRUCTIONAL FEATURES-3

Inner BeddingAnother protective layer over the metallic sheath for paper insulated cables to make it further non hygroscopicArmoringFor mechanical protection by providingSteel tapes for paper insulated cablesSteel strip / Steel round wires for PVC / XLPE CablesOuter Serving / Outer SheathFinishing of the cable with fibrous material impregnated in bitumen compound for PILC cables called outer servingPVC compound treated with anti-rodent anti-termite chemicals for PVC and XLPE cables

COMPARISON BETWEEN OHS & UGCS

SELECTION / SIZING OF CABLES

Cost Data Final

1Name of work: Painting of Transformer structure

S.No.ParticularsUnitQuantityRate (Rs.)Labour ChargesAmount (Rs.)

1PaintLtr3180150540

2SundriesLs30

SUB TOTAL OF MATERIAL COST570

3Add: 1) 2% on Transportation from Store to Site 2)1% on material cost towards watch and ward4%( On Material Cost)23

TOTAL593

4Add: Labour Charges150

5Add: Service Tax @10.2% on Labour Cost15

TOTAL758

6Add: 5%IDC Cost (On material and Labour)38

7Add:3% Contingencies (On Material and Labour)23

TOTAL819

Total819

2Name of work: Providing of copings to line structure

S.No.ParticularsUnitQuantityRate (Rs.)Labour ChargesAmount (Rs.)

1Cement ConcreteCMT0.25875116219

2SundriesLs40

SUB TOTAL OF MATERIAL COST259

3Add: 1) 2% on Transportation from Store to Site 2)1% on material cost towards watch and ward4%( On Material Cost)10

TOTAL269

4Add: Labour Charges116

5Add: Service Tax @10.2% on Labour Cost12

TOTAL397

6Add: 5%IDC Cost (On material and Labour)20

7Add:3% Contingencies (On Material and Labour)12

TOTAL429

Total429

3Name of work: Rectification of oil leaks to the transformer

S.No.ParticularsUnitQuantityRate (Rs.)Labour ChargesAmount (Rs.)

1Transport of Transformer to repair shed up and downLs1500

2Replacement of gaskets and filtering of oilLs800

3Installation Testing & CommissioningLs200

SUB TOTAL OF MATERIAL COST0

3Add: 1) 2% on Transportation from Store to Site 2)1% on material cost towards watch and ward4%( On Material Cost)0

TOTAL0

4Add: Labour Charges2500

5Add: Service Tax @10.2% on Labour Cost255

TOTAL2755

6Add: 5%IDC Cost (On material and Labour)138

7Add:3% Contingencies (On Material and Labour)83

TOTAL2976

Total2976

4Name of work: Providing Lightning Arresters

S.No.ParticularsUnitQuantityRate (Rs.)Labour ChargesAmount (Rs.)

19 kV Lightning ArrestersNo3499451497

2SundriesLs50

SUB TOTAL OF MATERIAL COST1547

3Add: 1) 2% on Transportation from Store to Site 2)1% on material cost towards watch and ward4%( On Material Cost)62

TOTAL1609

4Add: Labour Charges45

5Add: Service Tax @10.2% on Labour Cost5

TOTAL1659

6Add: 5%IDC Cost (On material and Labour)83

7Add:3% Contingencies (On Material and Labour)50

TOTAL1792

Total1792

5Name of work: Reconditioning of Earth pits (where earth Resistance is more than 10 )

S.No.ParticularsUnitQuantityRate (Rs.)Labour ChargesAmount (Rs.)

1Pipe earthsNo39006632700

2SundriesLs100

SUB TOTAL OF MATERIAL COST2800

3Add: 1) 2% on Transportation from Store to Site 2)1% on material cost towards watch and ward4%( On Material Cost)112

TOTAL2912

4Add: Labour Charges663

5Add: Service Tax @10.2% on Labour Cost68

TOTAL3643

6Add: 5%IDC Cost (On material and Labour)182

7Add:3% Contingencies (On Material and Labour)109

TOTAL3934

Total3934

6Name of work: Replacement of Damaged Bushings

S.No.ParticularsUnitQuantityRate (Rs.)Labour ChargesAmount (Rs.)

111 kV BushingsNo3105150315

2Sundries such as neoprene sheet etc.Ls85

SUB TOTAL OF MATERIAL COST400

3Add: 1) 2% on Transportation from Store to Site 2)1% on material cost towards watch and ward4%( On Material Cost)16

TOTAL416

4Add: Labour Charges150

5Add: Service Tax @10.2% on Labour Cost15

TOTAL581

6Add: 5%IDC Cost (On material and Labour)29

7Add:3% Contingencies (On Material and Labour)17

TOTAL627

Total627

7Name of work: Replacement of damaged Bushing Rods

S.No.ParticularsUnitQuantityRate (Rs.)Labour ChargesAmount (Rs.)

112/16 kVA Brass Rods with nutsNo71501401050

2Sundries such as washers etc.Ls50

SUB TOTAL OF MATERIAL COST1100

3Add: 1) 2% on Transportation from Store to Site 2)1% on material cost towards watch and ward4%( On Material Cost)44

TOTAL1144

4Add: Labour Charges140

5Add: Service Tax @10.2% on Labour Cost14

TOTAL1298

6Add: 5%IDC Cost (On material and Labour)65

7Add:3% Contingencies (On Material and Labour)39

TOTAL1402

Total1402

9Name of work: Rectification of GOS (AB Switch)

S.No.ParticularsUnitQuantityRate (Rs.)Labour ChargesAmount (Rs.)

1ContactsNo3200155600

2SundriesLs50

SUB TOTAL OF MATERIAL COST650

3Add: 1) 2% on Transportation from Store to Site 2)1% on material cost towards watch and ward4%( On Material Cost)26

TOTAL676

4Add: Labour Charges155

5Add: Service Tax @10.2% on Labour Cost16

TOTAL847

6Add: 5%IDC Cost (On material and Labour)42

7Add:3% Contingencies (On Material and Labour)25

TOTAL915

Total915

10Name of work: Rectification of 11 kV DOLO/HG Fuse set

S.No.ParticularsUnitQuantityRate (Rs.)Labour ChargesAmount (Rs.)

111 kV Fuse SetSet11710571710

2Sundries such as binding wire etc.Ls90

SUB TOTAL OF MATERIAL COST1800

3Add: 1) 2% on Transportation from Store to Site 2)1% on material cost towards watch and ward4%( On Material Cost)72

TOTAL1872

4Add: Labour Charges57

5Add: Service Tax @10.2% on Labour Cost6

TOTAL1935

6Add: 5%IDC Cost (On material and Labour)97

7Add:3% Contingencies (On Material and Labour)58

TOTAL2090

Total2090

11Name of work: Replacement of damaged Breathers

S.No.ParticularsUnitQuantityRate (Rs.)Labour ChargesAmount (Rs.)

1Silica gel BreatherNo1600100600

2Sundries such as Transformer oil etc.Ls50

SUB TOTAL OF MATERIAL COST650

3Add: 1) 2% on Transportation from Store to Site 2)1% on material cost towards watch and ward4%( On Material Cost)26

TOTAL676

4Add: Labour Charges100

5Add: Service Tax @10.2% on Labour Cost10

TOTAL786

6Add: 5%IDC Cost (On material and Labour)39

7Add:3% Contingencies (On Material and Labour)24

TOTAL849

Total849

12Name of work: Providing End Terminations (Alloy lugs) to line cables

S.No.ParticularsUnitQuantityRate (Rs.)Labour ChargesAmount (Rs.)

1Solder less Alloy lugsNo1630160480

2Sundries such as PVC tap etc.Ls30

SUB TOTAL OF MATERIAL COST510

3Add: 1) 2% on Transportation from Store to Site 2)1% on material cost towards watch and ward4%( On Material Cost)20

TOTAL530

4Add: Labour Charges160

5Add: Service Tax @10.2% on Labour Cost16

TOTAL706

6Add: 5%IDC Cost (On material and Labour)35

7Add:3% Contingencies (On Material and Labour)21

TOTAL762

Total762

13Name of work: Replacement of damaged / under sized PVC Cable

S.No.ParticularsUnitQuantityRate (Rs.)Labour ChargesAmount (Rs.)

1PVC insulated Cable (4 core - 150 mm)MTR6.02234001338

2PVC Cable 4 core - 150mmMTR30.0852550

3LugsNo1630480

4SundriesLs200

SUB TOTAL OF MATERIAL COST4568

5Add: 1) 2% on Transportation from Store to Site 2)1% on material cost towards watch and ward4%( On Material Cost)183

TOTAL4751

6Add: Labour Charges400

7Add: Service Tax @10.2% on Labour Cost41

TOTAL5192

8Add: 5%IDC Cost (On material and Labour)260

9Add:3% Contingencies (On Material and Labour)156

TOTAL5608

Total5608

14Name of work: Providing Fencing to Transformer structure (Where ground clearance is low)

S.No.ParticularsUnitQuantityRate (Rs.)Labour ChargesAmount (Rs.)

1SupportsNo6100600

2Barbed wireKg1045450

3SundriesLs30

4Labour for Supports erectionNo650300

5Labour for barbed wire layingKg1030300

SUB TOTAL OF MATERIAL COST1080

6Add: 1) 2% on Transportation from Store to Site 2)1% on material cost towards watch and ward4%( On Material Cost)43

TOTAL1123

7Add: Labour Charges600

8Add: Service Tax @10.2% on Labour Cost6161.2

TOTAL1784

9Add: 5%IDC Cost (On material and Labour)89

10Add:3% Contingencies (On Material and Labour)54

TOTAL54

Total1927

15Name of work: Tightening of Stays

S.No.ParticularsUnitQuantityRate (Rs.)Labour ChargesAmount (Rs.)

1Labour charges for TighteningLs160

SUB TOTAL OF MATERIAL COST0

3Add: 1) 2% on Transportation from Store to Site 2)1% on material cost towards watch and ward4%( On Material Cost)0

TOTAL0

4Add: Labour Charges160

5Add: Service Tax @10.2% on Labour Cost16

TOTAL176

6Add: 5%IDC Cost (On material and Labour)9

7Add:3% Contingencies (On Material and Labour)5

TOTAL190

Total190

16Name of work: Providing guy insulators for stays

S.No.ParticularsUnitQuantityRate (Rs.)Labour ChargesAmount (Rs.)

1Guy insulatorsNo42230088

27/10 GI WireKg250100

3Sundries .Ls60

SUB TOTAL OF MATERIAL COST248

4Add: 1) 2% on Transportation from Store to Site 2)1% on material cost towards watch and ward4%( On Material Cost)10

TOTAL258

5Add: Labour Charges300

6Add: Service Tax @10.2% on Labour Cost31

TOTAL589

7Add: 5%IDC Cost (On material and Labour)29

8Add:3% Contingencies (On Material and Labour)18

TOTAL636

Total636

17Name of work: Connecting PVC Cable to OH line by using PG Clamps

S.No.ParticularsUnitQuantityRate (Rs.)Labour ChargesAmount (Rs.)

1P.G. ClampsNo870240560

2Sundries .Ls40

SUB TOTAL OF MATERIAL COST600

3Add: 1) 2% on Transportation from Store to Site 2)1% on material cost towards watch and ward4%( On Material Cost)24

TOTAL624

4Add: Labour Charges240

5Add: Service Tax @10.2% on Labour Cost24

TOTAL888

6Add: 5%IDC Cost (On material and Labour)44

7Add:3% Contingencies (On Material and Labour)27

TOTAL959

Total959

18Name of work: Rectification of Neutral Earthing

S.No.ParticularsUnitQuantityRate (Rs.)Labour ChargesAmount (Rs.)

1Pipe earthsNo29004421800

2Sundries .Ls100

SUB TOTAL OF MATERIAL COST1900

3Add: 1) 2% on Transportation from Store to Site 2)1% on material cost towards watch and ward4%( On Material Cost)76

TOTAL1976

4Add: Labour Charges442

5Add: Service Tax @10.2% on Labour Cost45

TOTAL2463

6Add: 5%IDC Cost (On material and Labour)123

7Add:3% Contingencies (On Material and Labour)74

TOTAL2660

Total2660

19 AName of work: Providing LT Protection Kit for 25 kVA & 63 kVA Transformers

S.No.ParticularsUnitQuantityRate (Rs.)Labour ChargesAmount (Rs.)

1LT Protection KitNo111003001100

2Sundries .Ls100

SUB TOTAL OF MATERIAL COST1200

3Add: 1) 2% on Transportation from Store to Site 2)1% on material cost towards watch and ward4%( On Material Cost)48

TOTAL1248

4Add: Labour Charges300

5Add: Service Tax @10.2% on Labour Cost31

TOTAL1579

6Add: 5%IDC Cost (On material and Labour)79

7Add:3% Contingencies (On Material and Labour)47

TOTAL1705

Total1705

19 BName of work: Providing LT protection kit for 100 kVA & above Transformer

S.No.ParticularsUnitQuantityRate (Rs.)Labour ChargesAmount (Rs.)

1LT Protection with MCB and distribution BoxNo11371453513714

2Sundries .Ls100

SUB TOTAL OF MATERIAL COST13814

3Add: 1) 2% on Transportation from Store to Site 2)1% on material cost towards watch and ward4%( On Material Cost)553

TOTAL14367

4Add: Labour Charges535

5Add: Service Tax @10.2% on Labour Cost55

TOTAL14957

6Add: 5%IDC Cost (On material and Labour)748

7Add:3% Contingencies (On Material and Labour)449

TOTAL16154

Total16154

20Name of work: Providing Danger Plates

S.No.ParticularsUnitQuantityRate (Rs.)Labour ChargesAmount (Rs.)

1"DANGER" PlatesNo25020100

2Clamps with bolts and nutsNo24040

3Sundries .Ls10

SUB TOTAL OF MATERIAL COST150

4Add: 1) 2% on Transportation from Store to Site 2)1% on material cost towards watch and ward4%( On Material Cost)6

TOTAL156

5Add: Labour Charges20

6Add: Service Tax @10.2% on Labour Cost2

TOTAL178

7Add: 5%IDC Cost (On material and Labour)9

8Add:3% Contingencies (On Material and Labour)5

TOTAL192

Total192

Sheet1

Current carrying capacityThe current carrying capacity is not the same as specified at ambient temperature. The actual current carrying capacity of the cable laid in the ground depends on

Depth of the cable trench

Ground temperature

Thermal resistivity of the soil

Proximity to other cables

The actual current carrying capacity for the cable laid in the ground is

It = I A ( Rdt x Rsr x Rgt x RPC )

Short Circuit CurrentISC =

Where the

K is the constant depending upon the conductor material (Copper or Aluminum) and the initial and final temperatures during SC period.

A is the cross section of the core in sq.mm

t is the time duration(in Sec) of the short ciruit

Voltage dropIfl (RL Cos + XL Sin )

Losses Sheath losses

Dielectric losses

shall be minimum

Estimates

S.NoDescription of DefectUnitRate (Rs)QtyAmount (Rs)

1Painting of structuresNos819.006049,140.00

2Copings to be provided to structureNos429.001480634,920.00

3Oil Leaks to be rectifiedNos2,976.00216642,816.00

4Lightning Arrestors to be providedNos1,792.0012972,324,224.00

5Improvement Of Earthing System (Earth Resistance more than 10 Ohms)Nos3,934.002901,140,860.00

6HV Bushings Chipped / CrackedNos627.002415,048.00

7Damaged Bushing RodsNos1,402.001419,628.00

8Operating Rod (Telescopic Hot Stick/Hickery Rod)Nos8,000.0050400,000.00

9D.O.S Alignment not SatisfactoryNos914.003733,818.00

10HV DOLO SETS requir rectificationNos2,090.0070146,300.00

11Replacement of BreathersNos849.005647,544.00

12Lugs to be provided to cable endsNos762.001084826,008.00

13Under Size LT CableNos5,608.005733,213,384.00

14Inadequate Ground Clearance (Providing fencing)Nos1,927.00611,562.00

15Stay Sets to be TightenedNos190.0035767,830.00

16GUY insulators for the guysNos636.00267169,812.00

17PVC Cables not properly connected to OH LinesNos959.0014511,391,509.00

18Require Neutral Earthing RectificationNos2,660.004621,228,920.00

19 AReplacement of defective LV protection kit for 25/63 kVA TransformersNos1,705.009781,667,490.00

19 B-do- 100 kVA and above Transformers (Box type)Nos16,154.005879,482,398.00

20Danger PlatesNos192.001508289,536.00

Total23,802,747.00

Or Say Rs.2.38 crores

Inturrupts

Interruptions and Outages 11kv feeders in dodaballapur subdivision during year 2002-2003

Sl NoSub-stationFeeder 11KVFeeder_nameNo of outages During Reference Period 2002-2003Planned Shutdowns c)Total Interupption a+b+cDuration Other than planned shut downs a+b

< 30 min.(a)> 30 min.(b)

NosHrMin.NosHrMin.NosHrMin.NosHrMin.NosHrMin.

1"D" CrossDF-1LOCAL220335231402292013927223624433445

2DF-2RAGHUNATHPURA282494030515173133504852343531210045

3DF-3TALAGAVARA12516471434461285185267569381395133

4DF-4HANABE235353020324618859018443658342556816

5DF-5ANTHRAHALLY296392048825316061555047371834412213

6DF-6TELEPHONE-EXCHANGE14247251933402313112539239230161815

7DF-7LOCAL1679521030122183204295360877404

8DF-8SSGHATI146215421174016650010333539441673934

9DF-9RAJAGHATTA209421139632018549938433605924810531

10DF-10VASAVI64152021385062824914713659855410

11DF-12HEGGADIHALLY121321528514014538515294469101498355

12DF-13MELEKOTE983825349125135415302675452013212950

13KIADBKF-2BIRLASUPER2142915284751541324039620902427620

14KF-3INDUSTRIAL2473592940284425618140333715

15KF-4MARASANDRA

16KF-5KANSAWADI14518152134451451293531118235166530

17KF-6TULSYAN1842514950122115443530321415

18KF-7KSSIDC32915292140363820976915613055

19KF-8TOWN64815123112151214522725332763927

20KF-9BASETTYHALLY29114527385048495510410030565035

21KF-10JALIGE221311534451516115245416229152557630

22KF-11TAFE113201464519222044322525105

23DoddabelavagalaDBF-1NICHOLOUSEXPRESS4472093650314520848930534410

24DBF-2DODDABELAVENGALA30413045379055397320380295034122140

25DBF-3KANASAVADI260331043226103345103363043030325920

26DBF-4&6KONENAHALLI32251453310915587630413237303551610

27DBF-5HULIKUNTE29242623134555226103704022131517611

Total37857701064013921429905845387415800824425216224

Distribution Transformer failure During the above period

Distribution TransformerNo. of Failure% of Failures

No.

134822517

PowerTransformer failure During the above period

Power TransformerNo. of Failure% of Failures

No.

000

MBD0012EDAB.unknown