Bare Strandard AAC/AAAC/ACSR Conductors

Indo Alusys Industries Limited

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Company Information
A) Year Establishment B) Type Of Company C) Board of Directors Managing Director Director Director Director D) Our Banker's : : : : : : : 1979 Public Limited Mr.Pradeeep Jain Mr. M.K. Doogar Mr. A.P. Gandhi Mr. S.P. Singha State Bank Of Mysore State Bank Of Bikaner and Jaipur Development Credit Bank Indusind Bank Axis Bank 606, Tolstoy House, 15 Tolstoy Marg, New Delhi110001 RJ9509 SP-2/333, Industrial Area, Bhiwadi, Dist Alwar, Rajasthan, Indian 40 (Acre) [Cables & Conductors Plant in 5 Acre] RJ/4004/1383 (Mahavir Aluminium Limited) AAACH5489LXd001 08860850236 (Bhiwadi) AAACM5489L 0592055621 Total Nos. Strength - 780 Managerial - 47 Technical People - 15 Engineer - 25 Office Staff - 68 Factory Work Men - 650 Total Insulated Capacity (Assorted Sizes) 1.1 KV Power Cables (PVC/XLPE) 1.1KV Control Cables (PVC/XLPE) Railway Quad Cables Aerial Bunched Cables AAC/ACSR/AAAC Conductors XLPE Cables PVC Cables Aerial Bunch Cables AAC/ACSR/AAAC Conductors KMS/Year 2400 3000 2400 2400 6000 Tons

E) Registered Office F) Factory License No. G) Works Address H) Factory Area I) Registration With PF Regd. No. Excise Regd. No. CST/VAT & TIN No. Pan No. IEC No. J) Man Power

: : : : : : : : : :

K)

Production Capacity for Manufacturing Range

L)

BIS Licenses for Certification

IS: 7098(Pt - I) IS: 1554 & 694 (Pt - I) IS: 14255* IS: 398 (Pt - 1,2 & 4)

Indo Alusys Industries limited

AN ISO 9001 : 2000 COMPANY

Introduction
ABOUT US: Indo Alusys Industries Limited (Formerly Mahavir Aluminum Limited) promoted by Jain Group of Industries, with Turnover nearly to INR 200 Crore and expected to touch INR 800 Crore within next two years. We are one of the leading Manufacturer of Aluminum Products having its Works strategically located at Bhiwadi incorporated in the year 1979 with the main objective to manufacture quality Aluminum Extrusions in India and augmented its diversion capacity by inducting Cable & Conductor that will manufacture LT & HT Power Cables & Overhead Power Conductors upto 61 Strands as per relevant Indian & International standards under the brand name INDO CABLE. The plant is also accredited with ISO: 9001:2000 certification for maintaining stringent quality norms for manufacturing Cables & Conductor by KVQA Norway. BUSINESS VISION: Today, the essence of being successful in any business is merely not to apprehend and fulfill the customer requirements but to undertake the job with the cost effective way and also incorporating innovative and qualitative approach for accomplishment of the desired demand of the customer with their great satisfaction. So with this motto, the group is also capable to meet every demand & challenges by way of strict quality conscious approach strengthened by our sound technocrats having experience for last two decades by setting up an enterprises to manufacture Power Transmission conductors & Distribution Conductor & Cables to cater to the needs of the core sector and we are confident to put ourself as one of the largest manufacturer and supplier of LT as well as HT Cables & Overhead Power Transmission Conductors in India. We are also aheading to diversify ourself in Power Sector stepping into the business of EPC contractors for substation & Transmission Line Works. OBJECTIVE & ASPIRATION: Securing a market share did seem difficult with the competition already entrenched in the business. But the groups went ahead with a vision and an unswerving desire for the best and are convinced that offering the best technology and the services are not mere ingredients for success but a surefire way of staying in the business. So, we are moving with our Motto Superior technology & Superior solution. OUR STRENGTH: The organization was therefore structured to propagate these corporate objectives. Quality Control, Perfection, Efficiency, Professionalismwere not just mere buzz words but were given the sanctity of a prayer to be doggedly adhered to. The results were there to be seen. The group has already established itself as a grand edifice. And Indo Alusys Industries Ltd. has emerged as a force to reckon with.

Indo Alusys Industries limited

AN ISO 9001 : 2000 COMPANY

INTRODUCTION TO OVERHEAD CONDUCTORS

In the line design process, the most crucial decision often involves selecting the phase and ground conductors. The selection of conductors is critical since wind and tension loads that supporting structures must withstand are type of conductors used. Phase and ground conductors normally consist of multiple strands of aluminum, copper, and /or steel. Due to the stranding induced helical form of the individual strands, conductors exhibit lower composite rated breaking strength (4 to 11%), greater weight and higher resistance per unit length of conductor (2 to 4%) then would be obtained, were all the component wires parallel alone. Selection of the conductor depends upon factors, such as power requirements, governmental and environmental constraints, strength and electrical resistance stress-strain relationship, thermal characteristics and inductive and capacitive reactance. Array of conductors ranging standard AAC, AAAC, ACSR, ACAR, ACSR, AACSR and COPPER Conductor have been developed to meet the varying needs of the electrical utility engineer.

CONDUCTOR MATERIALS The most common type of phase conductors for overhead transmission lines is composed of strands of relatively pure aluminum; an aluminum alloy, and steel combined. Copper conductors are rarely used today because of their inferior conductivity-to-weight and strength-to-weight ratios and high costs. l All Aluminum ConductorsACC l Aluminum Conductors Steel ReinforcedACSR l All Aluminum Alloy ConductorsAAAC l Aluminum Alloy Conductors Steel ReinforcedAACSR l Aluminum Conductors Alloy ReinforcedACAR l Aluminum Conductor Al. clad Steel Reinforced ACSR/AS l Copper ConductorSingle Wire & Stranded l Insulated Conductor StrandsCopper/Aluminum

Indo Alusys Industries limited

AN ISO 9001 : 2000 COMPANY

CONDUCTOR SELECTION Tension loads, Wind loads, the current loading of the line, voltage stability, environmental affects losses, ambient conductions are all factors which must be considered to select a conductor. Selection should exemplify the best conductivity-to-weight ratio and/or strength-to-weight ratio at a minimal cost for the application. The electrical and mechanical properties, thermal properties, and stress-strain relationship of the conductor will dictate the choice of conductor type and size for a given design. In short, there may be conductors which offer some advantages in a par ticular line condition corresponding to other, Power line engineer should drive a balance between the advantages vis a vis needs of the line design. The following factors should be considered. l Lower electrical resistance resulting in higher conductivity l Lower thermal elongation resulting in less sag l Higher annealing temperatures allowing greater amp city l Superior tensile strength for larger spans and lower creep l Superior corrosion resistance top withstand all weather conditions l Lower weight to withstand ice loading & wind induced Aeolian violations. l Suitability for urban or rural usages.

Indo Alusys Industries limited

AN ISO 9001 : 2000 COMPANY

THE INDO ALUSYS INDUSTRIES LIMITED is emerging as pioneer global provider of power transmission conductor-started manufacturing and marketing Bare Aluminum Conductors for Overhead Power Transmission & Distribution Lines in 2008 and has relentlessly marched forward, being currently one of the leading manufacturers of the same in India. Professionalism of the highest caliber, inspired vision and drive for product innovation contributed to the success of the business in a competitive market both in the domestic front and exports. Within easy reach of the northern- Region has the manufacturing plants, located in the States of Rajasthan with present installed capacity for AAC, AAAC, ACSR, ACAR, ACSR, AACSR and COPPER Conductor & vast range of PVC / XLPE ,Railway Signaling ,Quad cable, Instrumentation cable & ABC Cables.

In very short span, the company has been consistently focusing to manufacture multi- stranded conductors of various sizes of AAC, AAAC, ACSR, ACAR, ACSR, AACSR and COPPER Conductor covering the entire range of high voltage transmission and distribution lines from 0.4 KV to 400 KV. Apart in domestic market, the INDO ALUSYS will created a reputation for its AAC, AAAC, ACSR, ACAR, ACSR, AACSR and COPPER Conductor in overseas market too and will share in line with bulk exports of AAC, AAAC, ACSR, ACAR, ACSR, AACSR and COPPER Conductor by executing export orders for conductors. As we continue to accord our self focusing on developing new energy saver product to meet the upcoming demands of market.

Indo Alusys Industries limited

AN ISO 9001 : 2000 COMPANY

ART OF MANUFACTURING
Aluminum or Copper Wires are drawn from high conductivity wire rods and then stranded in high speed stranders for 7,12,18,24 layers of wires, one over the other. The configuration of Conductors manufactured will vary according to the requirements of the Customer.

Aluminum alloy based conductors are being AAAC, types are solution treated and aged in specialty furnaces to achieve the perfect match of high mechanical strength and electrical Conductivity.

The finished Conductors are supplied in stranded forms as per the length specified by the buyers or conforming to relevant standards in wooden drums or as per customer requirements.

STANDARD AND QUALITY CONTROL

The manufactured Bare Aluminum Conductor - AAC, AAAC, ACSR, ACAR, ACSR, AACSR and COPPER Conductor carries the Indian Standard Certification marks (ISI), ASTM/BS/CSA/JIS/DIN which guarantees good quality in marking strategy and has found full acceptance in domestic as well as foreign markets conforming to its equivalent standards for AAC, AAAC, ACSR, ACAR, ACSR, AACSR and COPPER Conductor. The quality Strict in-process quality control is maintained at every stage of production from purchase or raw-material upto the finished product stage. A fully equipped team of Engineers and Sales Officers study individual Customer's requirements and offer free technical guidance on the choice and use of AAC, AAAC, ACSR, ACAR, ACSR, AACSR and COPPER Conductor. Our continuous and systematic efforts to Achieve High Standards of Quality have been recognized with Award of ISO9001-2000 Accreditation Certificate. The Company is managed by highly qualified technicians & professionally competent managers to sustain the high standards of efficiency & quality standards.

Indo Alusys Industries limited

AN ISO 9001 : 2000 COMPANY

RESEARCH, DEVELOPMENT & STRATEGY

More than its products, it is the strict adherence to high quality and on time deliveries that has brought the Company the name as reliable Supplier, which has helped not only to capture new markets but also winning appreciation from different Customers of the World. The Company has a Research & Development set up backed by sophisticated testing facilities which would enable development of advanced electrical conductor and wire products. Now in its operation, INDO ALUSYS is poised for further growth backed by the proven expertise, experience, and commitment to high quality and delivery schedule. Export Market Sales would also show remarkable growth in forthcoming years and look forward to meet specific needs of Conductors in building of Power Transmission and Distribution Lines. Strongly dedicated to power sector, INDO ALUSYS is coming up with up gradation of latest art of plant & machinery at its most sophisticated plant.

PRODUCT RANGE
l

l l

AAC, ACSR, ACAR, ACSR, AACSR CONDUCTORS UPTO 400 KV ALL ALUMINIUM ALLOY CONDUCTOR UPTO 400 KV CO P P E R CO N D U C TO R & OT H E R S P E C I A L CONDUCTORS AS PER CUSTOMER'S REQUIREMENT.

Indo Alusys Industries limited

AN ISO 9001 : 2000 COMPANY

STRANDARD BARE ALUMINIUM CONDUCTOR (AAC) IS-398-I : 1976

Code word Nominal Aluminium Area Sq. mm. Gnat Ant Wasp Special Conductor Spider Buttrfly 25 50 100 150 240 300 Stranding Sectional Area Sq. mm. 26.85 52.83 106.00 150.90 237.60 322.70 Approx. Overall Diameter mm 6.63 9.30 13.17 15.90 19.95 23.25 Approx. weight Kg/Km 74 1.45 290 415 654 888 Calculated Resistance at 20C. (Max) Ohm/Km 1.086 0.5525 0.2752 0.1942 0.1235 0.09107 Approx. Calculated breaking Load KN 4.52 8.25 15.96 23.28 35.74 48.74 Copper equivalent

No/mm 7/2.21 7/3.10 7/4.39 19/3.18 19/3.99 19/4.65

Sq. mm. 16 32 64 92 145 196

STRANDARD BARE ALUMINIUM CONDUCTOR STEEL REINFORCED (ACSR) IS-398-II : 1976 & IS : 398-V : 1992
Code word Mole Special Conductor Squirrel Weasel Rabbit Raccoon Dog Wolf Panther Kundah Zebra Moose Markulla Bersimis 18 20 30 50 80 100 150 200 400 420 520 560 690 6/1.96 6/2.11 6/2.59 6/3.35 6/4.09 6/4.72 30/2.59 30/3.00 42/3.50 54/3.18 54/3.53 42/1.13 42/4.57 1/1.96 1/2.11 1/2.59 1/3.35 1/4.09 7/1.57 7/2.59 7/3.00 7/1.96 7/3.18 7/3.53 7/2.30 7/2.54 18.10 20.98 31.61 52.88 78.83 105.00 158.10 212.10 404.10 428.90 528.50 562.70 688.90 21.12 24.48 36.88 61.70 91.97 118.50 194.90 261.50 425.20 484.50 597.00 591.70 724.40 5.88 6.33 7.77 7.77 12.27 14.15 18.13 21.00 26.88 28.62 31.77 31.63 35.04 73 85 128 128 319 394 726 974 1281 1621 2004 1787 2187 50 58 87 87 217 288 438 587 1120 1187 1465 1559 1907 23 27 41 41 102 106 288 387 161 434 539 228 280 1.618 1.394 0.9291 0.9291 0.3712 0.2792 0.1872 0.1391 0.07347 0.06870 0.05552 0.0599 0.04242 6.74 7.61 11.12 11.12 26.91 32.41 67.34 89.67 88.79 130.32 161.20 120.16 146.87 11 12 19 19 48 64 96 129 246 261 322 343 420 Nominal Aluminium Area Sq. mm. 10 Stranding Nos./mm Alum Steel 6/1.50 1/1.50 Sectional Area Sq. mm. Alum Steel 10.60 12.37 Approx. Overall Diameter mm 4.50 Approx. weight Kg/Km Total Aluminium Steel 43 29 14 Calculated Resistance at 20C (Max) Ohm/Km 2.781 Approx. Calculated breaking Load KN 3.97 Copper equivalent Sq. mm. 6

STRANDARD BARE ALUMINIUM CONDUCTOR STEEL REINFORCED (ACSR) BS-215-11-1970

Code word Gopher Weasel Fox Ferret Rabbit Mink Horse Dog Coyote Wolf Lynx Panther Jaguar Goat Bison Zebra Deer Moose Conductor Size Sq.mm. 25 30 35 40 50 60 70 100 130 150 175 200 200 320 380 400 425 525 Stranding Nos./mm Sq. mm. Aluminium 6/2.36 6/2.59 6/2.79 6/3.00 6/3.35 6/3.66 12/2.79 6/4.72 26/2.54 30/2.59 30/2.79 30/3.00 18/3.86 30/3.71 54/3.00 54/3.18 30/4.27 54/3.53 Calculated Sectional Area AlumiACSR nium 26.24 31.61 36.68 42.41 52.88 63.17 73.37 105.00 131.70 158.10 183.40 212.10 210.60 324.30 381.70 428.90 429.60 528.50 30.62 36.88 42.80 49.48 61.70 72.64 116.20 118.50 151.80 194.90 226.20 261.50 222.30 400.00 431.20 484.50 529.80 597.50 Overall Diameter mm ACSR 7.08 7.77 8.37 9.00 10.05 10.98 13.95 14.15 15.89 18.13 19.53 21.00 19.30 25.97 27.00 28.62 29.89 31.77 Approx. weight Kg/Km ACSR 106 128 148 172 214 255 538 394 521 726 842 974 671 1,489 1,443 1,622 1,973 1,998 Aluminium 72 87 101 117 145 173 203 288 364 437 507 586 580 896 1,055 1,186 1,187 1,461 Steel 34 41 47 55 69 82 335 106 157 289 335 388 91 593 888 436 786 537 Ultimate Strength Kg. 980 1,170 1,340 1,550 1,870 2,220 6,240 3,330 4,730 7,060 8,140 9,430 4,750 13,850 12,330 13,450 16,210 16,420 Calculated Resistance at 20C(Max) Ohm/Km 1.093 0.9077 0.7822 0.6766 0.5426 0.4546 0.3936 0.2733 0.2191 0.1828 0.1576 0.1363 0.1367 0.08912 0.07574 0.06740 0.06727 0.05470 Copper equivalent Sq. mm. 16 19 22 25 32 38 45 64 80 96 112 129 128 193 225 258 262 322

Steel 1/2.36 1/2.59 1/2.79 1/3.00 1/3.35 1/3.66 7/2.79 7/1.57 7/1.91 7/2.59 7/2.79 7/3.00 1/3.86 7/3.71 7/3.00 7/3.18 7/4.27 7/3.53

Indo Alusys Industries limited

AN ISO 9001 : 2000 COMPANY

STRANDARD BARE ALL ALUMINIUM ALLOY CONDUCTORS IS : 398-V : 1994

Actual Area mm2 15 22 34 55 80 100 125 148 173 200 232 288 346 400 465 525 570 604 642 695 767 Stranding and Wire Dia mm 3/2.50 7/2.00 7/2.50 7/3.15 7/3.81 7/4.26 19/2.89 19/3.15 19/3.40 19/3.66 19/3.94 37/3.15 37/3.45 37/3.71 37/4.00 61/3.31 61/3.45 61/3.55 61/3.66 61/3.81 61/4.00 Approx. Overall Dia mm 5.39 6.00 7.50 9.45 11.43 12.78 14.45 16.75 17.00 18.30 19.70 22.05 24.15 25.97 28.00 29.79 31.05 31.95 32.94 34.29 36.00 Approx. Mass Kg/Km 40.15 60.16 94.00 149.20 218.26 272.86 342.51 406.91 474.02 549.40 636.67 794.05 952.56 1101.63 1280.50 1448.39 1573.71 1666.00 1771.36 1919.13 2115.54 Calculated Resistance at 20C (max) Ohm/Km 2.3040 1.54010 0.9900 0.6210 0.4250 0.3390 0.2735 0.2290 0.1969 0.1710 0.1471 0.1182 0.0984 0.0829 0.0734 0.0651 0.0598 0.0568 0.0534 0.0492 0.0446 Approx. Calculated Breaking Load KN 4.33 6.45 10.11 16.03 23.41 29.26 36.64 43.50 50.54 58.66 58.56 84.71 101.58 117.40 136.38 146.03 158.66 167.99 178.43 193.25 213.01

STRANDARD BARE ALL ALUMINIUM ALLOY CONDUCTOR

Code Word Nominal Aluminium Area Sq.mm. Almond Cedar Fir Hazel Oak Ash Elm Upas 25 30 40 50 100 150 175 300 Stranding No/mm 7/2.34 7/2.54 7/2.95 7/3.30 7/4.65 19/3.48 19/3.76 37/3.53 Sectional Area Sq.mm. 30.10 35.47 47.84 59.87 118.9 180.7 211.0 362.1 Overall Diameter mm 7.02 7.62 8.85 9.90 13.95 17.40 18.80 24.71 Approx. weight Kg/Kmmm 82 97 131 164 325 497 580 997 Calculated Breaking load KN 8.44 9.94 13.40 16.80 33.30 50.65 59.10 101.50 Calculated Resistance at 20C Ohm/Km 1.094 0.9281 0.6880 0.5498 0.2769 0.1830 0.1568 0.09155

STRANDARD BARE ALUMINIUM ALLOY (AAAC) CONDUCTOR ASTM - B - 399 - 1992

Conductor Size MCM MCM MCM MCM MCM MCM MCM MCM MCM MCM MCM MCM MCM MCM MCM MCM MCM MCM MCM 30.58 48.69 77.47 123.30 155.40 195.7 246.9 312.8 394.5 465.0 559.5 652.5 740.8 927.2 1077.4 1165.1 1259.6 1348.8 1439.2 Stranding and Wire Dia No/mm 7/1.68 7/2.12 7/2.67 7/3.37 7/3.78 7/4.25 7/4.77 19/3.26 19/3.66 19/3.98 19/4.36 19/4.71 37/3.59 37/4.02 61.-/3.38 61/3.51 61/3.65 61/3.78 61/3.90 Sectional Area Sq. mm. 15.52 24.71 39.19 62.44 78.55 99.30 125.10 158.59 199.90 236.38 283.67 331.05 374.53 469.62 545.90 590.30 638.40 683.40 729.20 Approximate Overall Dia mm 5.04 6.36 8.01 10.11 11.34 12.75 14.31 14.30 18.30 19.90 21.80 23.55 25.13 28.14 30.42 31.59 32.85 34.02 35.10 Approximate Mass Kg/Km 43 68 108 172 217 274 345 437 551 650 781 911 1034 1295 1495 1617 1748 1872 1997 Calculated Resistance at 20C (max) ohm/km 2.163 1.356 0.8540 0.5371 0.4259 0.3376 0.2677 0.2113 0.1677 0.1421 0.1181 0.1014 0.0892 0.0712 0.0613 0.0568 0.0526 0.0490 0.0461 Rated Strength KN 4.93 7.84 12.5 19.8 24.0 30.2 38.1 48.4 59.0 69.6 83.6 97.5 108 136 156 169 182 195 208 Class

A A A AA, A AA, A A A AA, A AA AA AA AA AA AA AA AA AA AA AA

Indo Alusys Industries limited

AN ISO 9001 : 2000 COMPANY

PROCESS FLOW CHART ACSR CONDUCTOR

Aluminium Wire Rod (EC Grade)
Inspection 1 : Tensile Strength, Electrical Conductivity, Surface

AAA CONDUCTOR
Aluminium Alloy Wire Rod (W/T4 Temper)
Inspection 1 : Tensile Strength, Electrical Conductivity, Surface Inspection-1 Wire Drawing
To Final Wire Size

Reject

Inspection-1

Reject

Wire Drawing
To Final Wire Size

Inspection 2 : Diameter, Tensile Strength, Resistance Reject Inspection 3 : Tensile Strength, Resistance, Elongation

Inspection-2

Corrective action

Inspection 2 : Diameter, Tensile Strength, Resistance Galvanised Steel Wire/ Stranded Core Inspection 3 : Overall Diameter, Lay Ratio, Lay Direction, Surface

Inspection-2

Ageing

Conductor Stranding

Inspection-3 Wire Stranding

Corrective action

Inspection-3

Corrective action

Winding

Inspection 4 : Overall Diameter, Lay Ratio, Lay Direction, Surface

Inspection-4

Corrective action

Winding Inspection 4 : Length & Surface Inspection-4 Corrective action

Inspection 5 : Length & Surface

Inspection-5

Corrective action

Packing & Marking

Packing & Marking Reject/ Rework

Testing & Inspection Customer Inspection or Waiver

Testing & Inspection Customer Inspection or Waiver

Reject/ Rework

Despatch

Despatch

Indicates inspected & ACCEPTED

Indicates inspected & NOT ACCEPTED

Indo Alusys Industries limited

AN ISO 9001 : 2000 COMPANY

Indo Alusys Industries Limited

Head Office : 606, Tolstoy House, 15-Tolstoy Marg, New Delhi-110001, India Phone: 0091-11-23738011-12, 23312057, 23317857, 43564200-252 Fax: 0091-11-23312677 E-mail: info@indoalusys.com sales_cables@indoalusys.com rsingh@indoalusys.com Works : SP-2/333, Industrial Area, Bhiwadi, Distt: Alwar, Rajasthan, India Phone: 0091-1493-220786, 220868, 220924 Fax: 0091-1493-220786 Mobile:91-9672991451 E-mail: cables@indoalusys.com