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MANUFACTURING PEOCESS IN INDUSTRY-1
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MANUFACTURING PEOCESS IN INDUSTRY-2
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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.
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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.
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Global Energy Consulting Engineers, Hyderabad
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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.
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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
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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
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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
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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