This document is a training report submitted by Anil Nair about his training at Universal Cables Ltd. It includes sections on the company profile, various controllers used at the plant including temperature, diameter and power factor controllers. It also describes the basic process of manufacturing cables including VCV and CCV line extrusion. Other topics covered are automation using PLC panels, power distribution and the telephone exchange system.

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Universal Cables Ltd.
TRAINING REPORT
By Anil Nair
Under the guidance of
Mr. R.K. Mishra, General Manager (Electrical& Instrumentation)

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ACKNOWLEDGEMENT
Though words are seldom sufficient to express gratitude and feelings, I would
like to fulfill a fraction of my moralobligation by expressing a word of gratitude
to all those who have helped me to complete the training successfully.
First of all I would like to thank Mr. R.K.Mishra (General Manager, Electronics
and Instrumentation) UNIVERSAL CABLES LIMITED, for his guidance,without
which this training would have been incomplete.
I would like to thank Mr. Sudhir Jain, (Asst. Vice President, Administration),
UNIVERSAL CABLES LIMITED, Universal Cables Limited for accepting me as a
trainee and giving me opportunity to visit the company.
I would also like to thank all the staff member and wiremen at UCL for giving
suggestions, encouragement and support which have been instrumental in the
study.
Submitted by:
Anil Nair

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Content
 Company Profile
 Controllers
i) Temperature Controller
ii) Diameter Controller
iii) PF controller
 Cables
i) Basic Process of Manufacturing Cables
ii) VCV Line Extrusion
iii) CCV Line Extrusion
 Automation
i) PLC Panels
ii) CommunicationSystemof PLC withother Devices
 Power Distribution
 Telephone Exchange
i) EPABX

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Company Profile
UNIVERSAL CABLES LTD.
Universal Cables Limited (UCL) was established in the year 1962 as a modern
mass production unit to manufacturepaper insulated power cables in technical
collaboration with world's largestcable producer BICC, UK. Late Shri M.P. Birla,
who had adorned the chair of the Company for over 25 years since its
inception, enabled the Company to flourish in a highly competitive world,
while distinguishing itself by the latest technological tie-ups with the foremost
leaders in the world of this industry and the most up-to date technology.
Universal Cables Limited entered into a collaboration agreement with ABB high
Voltage Cables, Sweden in 1977 to manufacture cross-linked Polythene Power
Cable for the first time in the country. The Company is the foremost
manufacturer of XLPE Cables with modern dry cured dry cooled process for
voltage range extending from 1.1 to Extra High Voltage up to 132 KV grade.
Under the collaboration Agreement with ABB high Voltage Cables, Sweden,
UCL broughtin complete know how of compounding of Polymer and produced
complete range of dielectrics presently used in all special cables.
In 1983, UCL embarked on a joint venture with MPAVN to manufacture Jelly
Filled Telephone Cable in technical collaboration with one of the world's
leading manufacturers of Telephone Cable, Ericsson Cable AB, Sweden. This
plant was incorporated as Vindhya Telelinks Limited (VTL) and is situated at
Rewa, only 50Km away from its Power Cable Plant at Satna.

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Since 1985, ABB High Voltage Cables, Sweden, is further assisting UCL to
manufacture Fluroplastic Cables, specifically for very high temperature
operation and high frequency signalling circuitry.
In 1993, UCL & VTL jointly entered into the field of optical communication by
way of manufacturing Optical Fibre Cables in technical and financial
collaboration with Ericsson Cables AB, Sweden. This marked the birth of Birla
Ericssion Optical Limited (BEOL).
QUALITY CONSCIOUSNESS
Whether conventional or specially designed to any Indian or International
specification, UCL's products are put to the grill of rigorous in-process quality
cheeks by stage inspection and testing Its quality is taken as standard in the
world market.
MEANS ARE AS IMPORTANT AS THE END
UCL proudly claims to have the most sophisticated plant, equipment,
laboratory and testing facilities available in the country. The entire plant is
housed in dust-proof pressurized building to ensure consistency in the product
quality.
CERTIFICATION
The above claim is certified by various test authorities of the country like NTH,
Calcutta and CPRI Bhopal & Bangalore and all consultants like Ell, DCPL, M.N.
Dastur, Lloyds register of Shipping, MECON, Crown Agents and others. This
confirms the dependability and reliability of UCL products.
ISI MARKING
All standard UNISTAR cables are ISI marked.
IS/ISO QUALITY CERTIFICATION
UCL is accredited with IS/ISO 9001/2000 Quality Systems Certification in
recognition of the High Quality Standard of its cables. The company is also
accredited for its well-established environmental friendly activities and
atmosphere.

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TECHNICAL SERVICES
The Company welcomes enquiries on cable engineering problems and provides
solutions through its design and development team. Italso assists customers in
cable design to suit their specific requirement. A team of experts is always
ready to assist cable engineers for installation, laying and jointing cable
systems throughout the India. When requested the technical dept. of the
company provides help to customers for fault location and other related
problem.
RESEARCH & DEVELOPMENT
UCL emphasizes on in-house Research and Development. The R & D
programme is mainly directed to applied research for product development,
process development and technological up gradation. The R & D laboratory of
UCL is a recognized unit of Department of Scientific and Industrial Research of
Govt. of India. This laboratory has developed many new Cables for special
applications such as FRLS Cables, Ship wiring, Air craft wiring, Radars,
Submarine, Medical Equipments etc.
CAPACITORS
UCL set up its Capacitor Division in the year 1967, in technical collaboration
with world renowned TOSHIBA, to manufacture Paper & Power Capacitors. In
1977 this division entered into a technical collaboration with General Electric
Company of USA, to manufacture Mixed Dielectric Capacitors. Subsequently
the collaboration was extended to include All Polypro- propylene (All-PP)
Dielectric Capacitors impregnated with Non PCB oil. Today the Capacitor
Division is rated to be the foremostmanufacturer of All-PP Power Capacitors in
LT & HT range in the country.
This division offers complete schemes for power factor improvement and can
supply capacitors along with associated equipments on turnkey basis. It can
also carry out harmonic analysis of Power System on request and design &
supply Filter Banks. EXPORTS UCL also exports its products to various countries
of the world and has earned due recognition for its export efforts. Universal
Cables limited is a vibrant progressive company, a leader in its field of
activities, serving the aspiration of the nation in the field of Power
Development

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Controllers
What are controllers?
Controllers are devices, using mechanical, hydraulics or electronics techniques
often in combination, but in the form of a microprocessor or computer which
monitors and physically alters the operating condition of a given dynamic
system.
Types of Controllers
There are three basic types of controllers:-
 On-off controller
 PID Controller
Depending upon the systemto be controlled, the operator will be able to use
one type or another to controlthe process.
On/Off Controllers
On-off controllers are simplest form of control devices. The output from the
device is either on or off, with no middle state. There is not much control over
the process in this type on controllers. There occurs a continuous switching if
Controllers
On/Off
Controller
PID
Controllers

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the response time is very small. Due to continuous switching the other
sensitive devices in the system might get affected. On-off control is usually
used where a precise control is not necessary. These types of controllers are
mainly used in basic alarming system or switching systems.
PID Controllers
The third controller type provides proportional with integral and derivative
control, or PID. This controller combines proportional control with two
additional adjustments, which helps the unit automatically compensate for
changes in the system. These adjustments, integral and derivative, are
expressed in time-based units; they are also referred to by their reciprocals,
RESET and RATE, respectively. The proportional, integral and derivative terms
must be individually adjusted or “tuned” to a particular system using trial and
error. It provides the most accurate and stable control of the three controller
types, and is best used in systems which have a relatively small mass, those
which react quickly to changes in the energy added to the process. It is
recommended in systems where the load changes often and the controller is
expected to compensate automatically due to frequent changes in set point,
the amount of energy available, or the mass to be controlled.
Different Types of Controllers used in the System
There different types of controllers are present based on the application.
Controllers run on the basis of many physical quantities such as temperature,
capacitance, power factor etc. Some of the controllers which are used in the
plant are:
 Temperature Controller
 Diameter Controller
 PF controller
 Pressure Controllers

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Temperature Controller
A temperature controller is a type of
PID controller used to control the
process by taking an input from a
temperature sensor and has an output
that is connected to a control element
such as a heater or fan. It accurately
controls the process without extensive
operator involvement.
Working of a basic temperature controller
The temperature controller basic work is to monitor the temperature and
control the process. The thermocouple acts as the input for the temperature
controller. The controller then compares the actual temperature to the desired
control temperature or set point, and provides an output to a control element
mainly a contactor. If the detected temperature is lower than the set point the
command is sent through B1 (which is the output of the relay circuit) and the
contactor is turn on. When the target approaches the setpoint the switching
action takes place at a definite rate and the process is controlled. Once the
temperature is above the set point the contactor is switched off. Once the set
point is attained the contactor if switched off and unless and until the
temperature drops, the controller does allow the contactor to switched on.
Thus the temperature controller attains the control of the process.
Controller Circuit Diagram of working of Temperature
Temperature Controller

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Diameter Controller
Diameter controller is also a PID typeof controller. Itmonitors the diameter of
the cable and controls the process. It’s mainly used to control the line rate and
the extruder.
How diameter of a cable is measured?
Diameter is measured using different methods. Basic diameter detector
measures the diameter with the help
of a light source and a tray of photo
diodes. The cable is passed in
between the light source and the
tray of photo diodes. When the light
is emitted, it falls on the photo diode
and generates a voltage difference.
The light does not fall of the portion
of the tray which is the diameter of
the cable and those photo diodes do
not have a voltage. Detecting the
voltage the detector decides the
diameter of the cable.
Nowadays X-rays are used for this
purpose. The x-rays cut the
through the cable, and gives the
cross sectional view of it. This type
of diameter detectors are used
where cable is insulated with two
or materials and diameter helps a
curtail role in the quality of the
cable.
Basic Diameter Detector
Output of Sikora Detector (One of the X-ray
diameter detectors used in the plant)

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Basic working of diameter controller
Diameter controller is basically used for maintaining the desired thickness of
the insulation of the cables. Diameter controller takes the input from the
diameter detector (Dia-head). If the diameter of the cable is less than the set
point, then the controller will decrease the line rate or increase the rpm of the
extruder. If the diameter is more than the set point then the controller
increases the line rate or decreases the rpm of the extruder thus maintaining
the diameter of the cable.
PF Controller
Power factor controller or PF controller
is a controller with the help of which
the power factor in the power supply
line can be controlled and the power
loss can be controlled.
What is power factor?
Power factor is the ratio of the real
power and the apparent power drawn
by the electrical load.
𝑃𝑜𝑤𝑒𝑟 𝑓𝑎𝑐𝑡𝑜𝑟( 𝑃. 𝐹. ) =
𝑅𝑒𝑎𝑙𝑃𝑜𝑤𝑒𝑟( 𝑘𝑤)
𝐴𝑝𝑝𝑎𝑟𝑒𝑛𝑡𝑃𝑜𝑤𝑒𝑟( 𝑘𝑉𝐴)
Why power factor correction is very important?
In industries due to the motors and other heavy coiling machineries, a lag is
created in the phase of the voltage and current. This results in the formation of
the apparent power.
𝐴𝑝𝑝𝑎𝑟𝑒𝑛𝑡 𝑝𝑜𝑤𝑒𝑟 =
𝑅𝑒𝑎𝑙 𝑝𝑜𝑤𝑒𝑟
𝑃𝑜𝑤𝑒𝑟 𝑓𝑎𝑐𝑡𝑜𝑟
The apparent power is always greater than the real power as a result there will
be a power loss. The power loss can be controlled if the power factor is made
unity.
A PF controller

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𝐴𝑝𝑝𝑎𝑟𝑒𝑛𝑡𝑃𝑜𝑤𝑒𝑟( 𝑘𝑉𝐴)
𝑅𝑒𝑎𝑐𝑡𝑖𝑣𝑒 𝑃𝑜𝑤𝑒𝑟(𝑘𝑉𝑎𝑟)
ᵩ
𝑅𝑒𝑎𝑙𝑃𝑜𝑤𝑒𝑟( 𝑘𝑤)
The relational between the apparent and real power can be explained with the
right angled triangle. An angle is created between the apparent and real power
called𝛷. The power factor can be said to be equal tocos 𝛷. So if the angle
between the apparent and the real power is reduced and made to tend to zero
so the power factor tend to unity. By doing this the power loss is controlled.
How does a P.F. controller work?
The power factor controller or the PF controller monitors the power factor of
the supply line and checks whether the power factor is near to the unity or not.
If the current is lagging the power factor pass the supply line through the
suitable capacitor banks and make the current to be in phase with the voltage.
If the power factor is equal to the set power factor then the capacitor banks
are switched off and the power factor is monitored.

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Cables
Introduction
The electrical current in a conductor causes a voltage drop and power losses.
The temperature rise in the cable caused by the losses must be kept within
certain limits order not to shorten the service life of the cable. The
temperature limit varies with the type of cable, or more precisely the type of
insulation. The best way to keep the temperature within limits specified for the
type of cable is to choose the conductor cross-section so that the cable and its
surroundings with the actual continuous load achieve thermal balance at a
temperature below or equal to the temperature limit recommended. Cable
type and size should be selected keeping in view the following:-
 Application
 Working voltage; earthed or unearthed neutral system
 Load current, load factor, starting duty and frequency
 Installation method
 The environment in which the cable has to operate
 Short circuit current and system protection
 Acceptable voltage drop
 Economies
How the above factors influence on the choice of cable?
1) Application: Application of the cable determines the basic factors for the
choice of cable type and the rules according to which it must be
manufactured. Following are the major factors for choice of cable type.
a) Conductor materials: No doubt copper is better conductor material
owing to its high electrical conductivity and other electrical/mechanical
properties but due to its high cost and scarcity, researches are being
carried out to find other cheaper and abundant metals which may be a
close substitute to copper in electrical application. Aluminium
conductors are being used in place of copper conductors for the past
many years and have proved to be quite satisfactory. The lower

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conductivity of an Aluminium (61% of the annealed copper) results in
increased dimensions of the cable and ultimately of conduits and fittings
for the same current carrying capacity as that of a copper conductor
cable. Aluminium conductor cables although bigger and somewhat
stiffer when lower number of wires is used for the conductor than the
equivalent copper conductor cables, are still flexible enough to be
installed where a copper conductor cable was formerly used. The
advantages of the lighter weight offset the disadvantages of larger sizes
for a given capacity. The use of Aluminium conductor cables should be
preferred as far as possible. The use of flexible copper conductor is
recommended where very high degree of flexibility is required as in the
case of mines etc.
b) Insulating materials: The right type of insulation material for a particular
usagedepends upon the voltage grade, operating temperature required,
degree of flexibility, current capacity requirement and restrictions on
size etc. and other climatic conditions.
c) Metallic Sheathing: Either pure lead or different lead alloys are used for
Sheathing of PILC cables or each has its own advantages. The most
common and popular alloy is lead Alloy 'E'.
d) Bedding and Serving materials: In case of PVC cables the normal
bedding and serving material is PVC compound. The normal bedding and
serving in case of PILC cables consistof a combination of an impregnated
paper, cotton and Hessian tapes and bituminous compound. These
materials provide protection against corrosion of armour and lead and
are suitable in great majority of installations. However, in special cases
where severe chemical corrosion is to be encountered, the use of PVC
bedding and PVC serving is recommended.
e) Armouring: The purpose of armour is to provide mechanical protection
to the cable and to facilitate earthling for safety requirements. This also
carries phase to ground fault currents of the system safely. Double steel
tape provides good mechanical protection but when in addition
longitudinal stresses are encountered during the installation or in
service, steel wire/strip armouring is recommended for vertical
armouring should be preferred. Double wire runs, river crossing, cables

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laid on bridges and mine shafts etc. where longitudinal stresses are
expected.
2) The system voltage determines the voltage class of the cables.
3) The current rating is, in general, the decisive factors for fixing conductor
cross-section. But in certain applications where intermittent load is
required, it is more relevant to use the squared average r.m.s. current with
a reduced cross section.
4) The power cables must be capable of carrying, the required normal full load
current continuously under the site conditions throughout the year.
Therefore, the currentratings specified must be corrected to site conditions
by applying suitable derating/uprating factors depending upon –
a) Ground or ambient air temperature (max.)
b) Thermal resistivity of soil during dry season.
c) Total number of cables/circuits in groups.
5) Chemical substances in the environment might cause special stringent
requirements on the outer covering. If it is necessary to reduce the
propagation of fire along cable route combined with low corrosivity, toxicity
and smoke generation characteristics for cables, "FRLS' cables (Flame
Retardant low Smoke) with thermoplastic or thermosetting material or fire
survival cables with elastomeric material should be used. These types of
cables are designed with special composition of protective sheath
materials, and by using beat barrier tapes etc. for use in such critical fire risk
installations.
6) Short circuit current together with duration of short circuit determines the
short circuit energy the cable insulation has to with stand thermally. In
certain cases a larger size of cable then the cable required for normal full
load current may be needed to match system short circuit current levels.
Voltage drop is also a major factor in deciding the conductor size of the
cable. The cross section of the cable should be chosen such that voltage
drop of the cable for the given route length does not exceed the statutory
requirement.

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7) Naturally, the most economical construction and the size of the cable
consistent with required current carrying capacity and laying condition has
to be selected. Thus the selection of particular type of cable i.e. PVC, XLPE,
PILC or rubber and the particular material for screening, sheathing,
bedding, armouring or serving etc. out of many choices available depends
upon the usages, laying and climatic conditions. The design of the cable for
a particular application must be optimized taking into account all the
above-mentioned factors. In case expert guidance in this respect is desired,
please contact UCI Technical Service Division. UCL SATNA
Manufacturing process of Cables
The different stages of manufacturing consist of the following different types of processes:
 Wire Drawing – Annealing
 Tinning
 Bunching
 Stranding
 Insulation
(For Paper/PVC/Rubber/XLPE/Fluroplastic/Polythelene)
 Laying
 Impregnation
 Lead Sheathing
 Bedding – Extruded/wrapped/fibrous lapping
 Armouring
 Round wire/Flat strip/Steel tape
 Sheathing/ Serving
 Extruded/Fibrous lapping
The details of above manufacturing processes are as follows:
Conductor:
Wires of different sizes are drawn from Aluminium/Copper rods on wire-
drawing machines. The size (diameter) of wire depends upon the overall cross
sectional area of the ultimate cable under manufacture as well as the flexibility
requirement. Annealed copper Wires for flexible rubber cables are then tinned
before they are released for next process. The tinning is done by passing the
cleaned cu. wires seated with the flux through molten tin both. The excess of
tin adhering to wire surface is wiped out by means of wipers.

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Stranding:
The Al or Cu. wires or tinned copper wires as the case may be are
bunched/stranded together. The direction of stranding of alternate layers is
always kept in opposite direction in order to have tight and balanced
configuration of wires. The standard Conductor may be compact circular or
shaped as per the cable construction.
Insulation:
PVC: Different type of PVC compounds are used for required Physical &
electrical properties and continuous operating temperature of cables. PVC
compound extruded over conductor by extrusion process on different sizes of
extruders as per the size of conductor. In line to extrusion process H.V. testing
(Spark testing) is being done to check the quality of extruded core.
Rubber - Natural or synthetic rubber based compounds are prepared to meet
the physical & Elec. properties and continues operating temperature of cable.
Various types of rubber compounds are then extruded over the conductor as
per the requirement of the customer.
Paper insulation - In this case insulated paper tapes are lapped on conductor.
The thickness of insulation is built up by required number of paper tapes
according to voltage grade of cables. The top layer of paper tapes is suitably
numbered for core identification.
XLPE – XLPE cables have become very much popular now a day. These cables
are replacing paper-insulated cables right from low voltage grade to extra high
voltage grade. In these cables two types of constructions areused i.e. screened
and unscreened. 11 KV and above grade cables are all screened. Conductor
screen, insulation and insulation screen are generally applied in one operation
called dual-tandem process. M/s Universal Cables Ltd is one of the pioneer
cable manufacturers of XLPE cable up to 132 KV grade cables in INDIA.
Vulcanization/Cross-linking:
Rubber and XLPE cables are vulcanized after extrusion. This process is done
just after extrusion on CV/CCV/PLCV lines. This process is done to improve the
electrical and physio-mechanical properties of rubber and polyethylene

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compounds. In some cases batch vulcanization is carried out for rubber cables
and low voltage XLPE cables.
Laying up of cables:
The insulated cores are laid up along with filling material and twisted to get
approximate circular Cable. A binding tape is also provided to hold the fillers
and maintain the circularity of laid up cables.In case of paper-insulated cables
if the cables are belted type, belt insulation is done along with laying up
process by providing required no. of paper tapes and in screened type cables
copper woven fabric tape is provided over laid up cores.
Impregnation process:
Paper insulated cables need a special process known as impregnation. The
function of this process is to extract moisture out of paper insulation and
impregnate the insulation with moisture resistant insulating compound.
Heating the Cable under vacuum for some period and then filling the insulating
compound over cable within the impregnating vessel do this process. The cycle
of drying flooding and cooling etc. depends on sizeand voltage grade of cables.
By impregnation the electrical properties of paper insulation are enhanced.
Procedure adopted for drying and impregnation of paper-insulated cables
comprises the following stages:
 Rewinding the cables in impregnation trays
 Loading the trays in the impregnation tanks
 Heating the cables under vacuum
 Impregnating of cables with impregnation compound for required
period
 Unloading the cable-trays from the tanks after impregnation.
 The compound used for impregnation is a petroleum product and has
excellent electrical and mechanical properties.
Lead sheathing:
After impregnation, lead sheath is applied over the paper-insulated cables. This
process is done by sleeve extrusion (pipe extrusion). The object of Lead

19. 19
sheathing is to prevent the entry of moisture in the impregnated cable while
maintaining the flexibility of cable.
Inner Sheathing/Bedding:
PVC and Rubber insulated cables are provided with inner sheathing over laid
up cores as bedding for armouring. In case on PVC cables inner sheathing may
be done by lapping PVC/PE tapes or by PVC extrusion but in case of rubber
insulated cables rubber extrusion is done for this purpose.Armouring The
armouring is provided to provide mechanical protection of cables during
handling and installation. This is done by providing galv. round steel wires or
galvanised steel strips or double steel tapes over the bedded cables.Though
the main function of armouring is to protect the cable from outside mechanical
damages to the cable but it also serves the purposeof carrying the short circuit
current produced during system failure or any type of short circuit in the
system.
Sheathing/Serving:
After armouring or in case of un-armoured cables, the laid and bedded cables
are provided with a protective sheathing of extruded PVC or PE sheath. Paper
insulated cables are generally provided with a fibrous lapped serving but PVC
or any other type of extruded sheath can also be given if required.
Final testing:
All cables are rewound in proper size wooden/steel reels and sent to testing
section where all the cables are subjected to rigorous electrical and physical
tests. Both the ends of cables after testing are sealed and given a unique
identification number. These are then handed over to marketing department
for onward dispatch to relevant customer
Quality control
In universal cables quality is maintained by following an inbuilt quality system
which is based on international specification IS/ISO 9001.Products are tested
and processes are controlled at all stages of manufactures from raw material
to the finished stage. In addition certain standards procedures are adopted in
order to ensure that product successfully fulfils the customer requirement.

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Extra high Voltage XLPE Cables
Introduction:
UNIVERSAL CABLES LTD, the pioneer of XLPE cables in India, manufactures
Extra High Voltage (EHV) XLPE cables in the range of 66-220 kV using ‘Vertical
Continuous Vulcanizing (VCV) technology in technical collaboration with World
Leader in Cable manufacturing, FURUKAWA ELECTRIC CO. LTD. (In association
with VISCAS Corporation, Japan). This technology for EHV XLPE Cable
manufacturing process is the only of its kind in the Country.
EHV Underground Power Transmission is the solution for meeting today’s
growing power demand of the power starved Metro Cities. Underground
Power Transmission System requires highest reliability to ensure
uninterrupted power supply.
The main cutting edge features of this technology as True simultaneous triple
extrusion with single (common) cross-head, Dry cure dry cooled process,
Dimensional accuracy for perfect geometry with Zero eccentricity/ovality of
the insulation, Class 1000 cleanliness level with completely closed material
handling system, Online X-Ray monitoring system, Direct gravitational feeding
of XLPE compound, Control and Monitoring in production process using
SCADA, all add up to unmatched quality standard to ensure reliable and
efficient performance of the cable throughout its service life.
Process of Manufacturing EHV XPLE:

21. 21
Extrusion and Curing rocess VCV
Line
The system adopted for insulation of
EHV XLPE cable is DRY Curing for
cross linking in Vertical Continuous
Vulcanizing(VCV). The VCV line
having common head for triple
extrusion ensures excellent
concentricity, prefect bonding of
insulation and semiconducting
layers, smooth interfaces free from
protrusions provides superior di-
electric properties for very high
voltage cable. On-line monitoring
and controlin the production process
ensures adherence to specified Nd
strict dimensional standards. The
process adopted for cross linking
ensures that the cables are kept
absolutely dry during the curing
process. This eliminates the chances
of electrochemical treeing during the
full life of the cable. The outstanding
characteristic of XLPE cables
manufactured by VCV line are:
 True simultaneous triple extrusion with single (common) cross head
conductor screen, insulation and insulation shield applied in single
process. This provides perfect bonding of tinsulation and semicon
layers with smooth boundary and free of protrusions.
 Completely dry curing process prevents formulation of micro voids
and eliminates mositure contents in the XLPE insulation . This also
prevents electrochemical tree fromulation in the insulation and
capable to withstand higher stress voltage.
 Dimensional accuracy with prefect geometry with zero
eccentricity/ovality of the insulation. Theis enables uniform stress
distribution over the insulation.
 Class 1000 cleanliness level in manufacturing with completely closed
material handing system. This prevents insulation contamination
which is an imperative for Extra High Voltage Cables enabling high
impulse and breakdown voltage levels.
VCV Plant

22. 22
HV/MV XPLE Cables
Extrusion and Curing at CCV Line

23. 23
Key features of Continuous
Catenary Vulcanization (CCV)
line
 HV/MV XPLE cables are
insulated
 Triple headed cross
linking extruder
 Diameter is controlled
using SIKORA X-ray
type diameter
controller.
 HMI controlled heating
zones.
HMI controller display of CCV Line

24. 24
AUTOMATION
Introduction
Automation refers to a process of optimization of energy consumption (Heat,
Light, Fuels, water etc.), and optimization of operation and maintenance cost
through a closed loop direct digital and analog control. Supervision and
regulation of the various service equipments, using computer network with
field interface units (I/O Modules) and signal conditioners (Sensors and signal
converters).It facilitates in remote operation of equipments. It replaces
hardware wired annunciaters, mimic panels, and local control desks.
Importance of Automation
The manufacturing process which considered to be highly dynamic as variances
occur at each stage of input. An expert operator is, however, required to run
the plant in a stable condition at all times. Moreover, each operator response
to given situation may be different. Hence, a software solution consisting of
fuzzy logic, regression analysis, neural networks are required to capture the
expert knowledge to take action well in advance to achieve optimization on a
continuous basis.
Automating System
 PLC
 NETWORK
 SCADA
 DCS
 CONTROLLERS
Introduction to PLC
A PLC is a device which replaces the necessary sequential relay circuits for
machine control. A PLC can be considered as a versatile version of such a
controller. It is a device, which can accept multiple inputs, of different kinds, of
different voltage levels, from various different devices and different parts of a
process or a machine. Based upon the state of these inputs the PLC acts
further. It controls various devices by turning on/off the outputs that these
devices are connected. The logic on which the inputs are related to the outputs

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or the Logic by which the devices connected to PLC are controlled can be
programmed, thus the name Programmable Logic Controller.
The programming of a PLC is generally done through
programming software or a dedicated programming terminal. Because of this
flexibility of programming that a PLC offers a PLC finds many different, almost
endless applications in the industry. A PLC can be programmed and
reprogrammed to suit to just about any application that one can think of.
PLC's have a wide area of applicability, in Machining,
Material Handling, Automation etc.
PLC ARCHITECTURE
Memory Section
Stores user logic, state RAM, system overhead in battery backed CMOS RAM &
system’s executive firmware in nonvolatile ROM.
CPU Section
Solves the user logic program based on the current input values in state RAM,
then updates the output values in state RAM.
I/O processing Section
Directs the flow of signals from input modules to state RAM and provides a
path over which output signals from CPU’s logic solve are sent to output
module.
Communication Section
Communication section helps PLC to communicate with programming panels,
host computers, hand-held diagnostic tools, and other peripheral (master)
devices as well as with other PLCs and nodes on a communication network.

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Block Diagram of PLC
Basic PLC operation
PLCs consist of input modules or points, a Central Processing Unit (CPU), and
output modules or points. An input accepts a variety of digital or analog signals
from various field devices (sensors) and converts them into a logic signal that
can be used by the CPU. The CPU makes decisions and executes control
instructions based on program instructions in memory. Output modules
convert control instructions from the CPU into a digital or analog signal that
can be used to control various field devices (actuators). A programming device
is used to input the desired instructions. These instructions determine what
the PLC will do for a specific input. An operator interface device allows process
information to be displayed and new control parameters to be entered.

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Communication System of PLC
Communication is mainly used by plc for communicating with the drives and
other field devices. The communication channel is used for data exchange and
passing the commands to control the system.
There are basically four types of protocols are used for Communication:
 USS Protocol
 PROFIBUS Protocol
 Modbus Protocol
 PROFINET Protocol
PROFIBUS protocol is mainly used for the communication between the PLCs
and other devices.
PROFIBUS Protocol:
PROFIBUS protocol is commonly used type of protocol for communication
between different devices and PLC. It is a standard for fieldbus communication
in automation technology and was first promoted by BMBF (German
Department of Education and Research) and was later used by Siemens.
Twisted pair cables or fibre cables are used as physical media and bus type
topology is used.
PROFIBUS Protocol(OSI reference Model)
OSI Layers:
1. Physical Layer
2. Data link
3. Network
4. Transport
5. Session
6. Presentation
7. Application

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To utilise these functions, various service levels of the DP protocol were
defined:
 DP-V0 for cyclic exchange of data and diagnosis
 DP-V1 for acyclic exchange of data and alarm handling
 DP-V2 for isochronous mode and data exchange broadcast (slave-to-
slave communication)
Security Layer
The security layer FDL (Field bus Data Link) works with a hybrid access method
that combines token passing with a master-slave method. In a PROFIBUS DP
network, the controllers or process control systems are the masters and the
sensors and actuators are the slaves. Various telegram types are used. They
can be differentiated by their start delimiter (SD):
No data: SD1 = 0x10
SD1 DA SA FC FCS ED
Variable length data: SD2 = 0x68
SD2 LE LEr SD2 DA SA FC DSAP SSAP PDU FCS ED
Fixed length data: SD3 = 0xA2
SD3 DA SA FC PDU FCS ED
Token: SD4 = 0xDC
SD4 DA SA ED
Brief acknowledgement: SC = 0xE5
SC
SD: Start Delimiter

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LE: Length of protocol data unit, (incl. DA, SA, FC, DSAP, SSAP)
LEr: Repetition of protocol data unit, (Hamming distance = 4)
FC: Function Code
DA: Destination Address
SA: Source Address
DSAP: Destination Service Access Point
SSAP: Source Service Access Point
SAP (Decimal) SERVICE
Default 0 Cyclical Data Exchange
(Write_Read_Data)
54 Master-to-Master SAP
(M-M Communication)
55 Master-to-Master SAP
(M-M Communication)
56 Read Inputs (Rd_Inp)
57 Read Outputs
(Rd_Outp)
58 Control Commands to
a DP Slave
(Global_Control)
59 Read Configuration
Data (Get_Cfg)
60 Read Diagnostic Data
(Slave_Diagnosis)
61 Send Parameterization
Data (Set_Prm)
62 Check Configuration
Data (Chk_Cfg)
Note: SAP55 is optional and may be disabled if the slave doesn't provide non-
volatile storage memory for the station address.

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PDU: Protocol Data Unit (protocol data)
FCS: Frame Checking Sequence
ED: End Delimiter (= 0x16!)
The FCS is calculated by simply adding up the bytes within the specified length.
An overflow is ignored here. Each byte is saved with an even parity and
transferred asynchronouslywith a start and stop bit. There may not be a pause
between a stop bit and the following start bit when the bytes of a telegram are
transmitted. The master signals the start of a new telegram with a SYN pause
of at least 33 bits (logical "1" = bus idle).
PLC Panel

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Introducing the S7-200 Micro PLC
The S7-200 series is a line of micro-programmable logic controllers (Micro
PLCs) that can control a variety of automation applications. Figure 1-1 shows
an S7-200 Micro PLC. The compact design, expandability, low cost, and
powerful instruction set of the S7-200 Micro PLC make a perfect solution for
controlling small applications. In addition, the wide variety of CPU sizes and
voltages provides you with the flexibility you need to solve your automation
problems.
Advantages
 Smaller physicalsize than hard-wiresolutions.
 Easier and faster to make changes.
 PLCs have integrated diagnostics and overridefunctions.
 Diagnostics arecentrally available.
 Applications can be immediately documented.
 Applications can be duplicated faster and less expensively.
Ladder Logic
Elements
Symbols Meaning
-| |- Normally open contact
-| |- Normally closed contact
-|P|- Positive Transition contact
-|N|- Negative Transition contact
-( )- Normal Coil
-(L)- Latched Coil

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POWER DISTRIBUTION
 Incoming supply line from the State Electricity Board is 33kv.
 At UCL, there are two substations:
i) At the main substation 3000kVA x 3 transformers are installed.
ii) At the VCV Line substation 2000kVA x 2 transformers are installed.
 Incoming for main substation and VCV substation is 33kV and output of
main substation and VCV substation is 415V 3-Phase + N
 Captive Power
At the power house following DG (Diesel Generator) sets are installed.
i) 500kVA x 6 (DG sets are installed)
ii) 1550kVA x 2 (DG sets are installed)
iii) 2100kVA x 1 (DG sets are installed)
Total captive power = 8200kVA or 8.2MVA
 State Electricity Supply Voltage power = 33kV
 Contract Demand = 4000kVA
 Maximum Demand = 3600kVA (M.D. is always 10% less than the C.D.)
3-phase Distribution
Primary
Voltage between:
R-Y, Y-B, R-B= 33kV
Current(I)=87Amp
Secondary
Voltage between:
R’-Y’, Y’-B’, B’-R’ =Vph/√3=415V
Voltage between:
R’-N, Y’-N, B’-N= 230V
Current(I’)=7000Amp

33. 33

34. 34
TELEPHONE EXCHANGE SYSTEM
Telephone exchange system at UCL is based on the Time Division Multiple
Access (TDMA). Time division multiple access (TDMA) is a channel access
method for shared medium networks. Itallows severalusers to share the same
frequency channel by dividing the signal into different time slots. The users
transmit in rapid succession, one after the other, each using its own time slot.
This allows multiple stations to share the same transmission medium (e.g.
radio frequency channel) while using only a part of its channel capacity. TDMA
is used in the digital 2G cellular systems such as Global System for Mobile
Communications (GSM), IS-136, PersonalDigitalCellular (PDC) and iDEN, and in
the Digital Enhanced Cordless Telecommunications (DECT) standard for
portable phones. It is also used extensively in satellite systems, combat-net
radio systems, and PON networks for upstream traffic from premises to the
operator.
TDMA is a type of Time-division multiplexing, with the special point that
instead of having one transmitter connected to one receiver, there are
multiple transmitters. In the case of the uplink from a mobile phone to a base
station this becomes particularly difficult because the mobile phone can move
around and vary the timing advance required to make its transmission match
the gap in transmission from its peers.
Siemens make High IP Ready 4300 EPABX (Electronic Private Automatic Branch
Exchange) system is installed at the telephone exchange supported by PIR
cards of 30 channels with 2Mbs speed. Two analog trunk extensions are used.
LTUCX is used for interconnecting different stages of EPABX. Digital enhanced
cordless telephone is used with the help of DECT cards, which are connected to
EPABX connected to the trans-receiver base station.
EPABX
EPABX: These are solid state digital systems.EPABX mainly havethe following
features:
 Establishing connections (circuits) between the telephone sets of two
users (e.g. mapping a dialed number to a physical phone, ensuring the
phone isn't already busy)

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 Maintaining such connections as long as the users require them (i.e.
channeling voice signals between the users)
 Disconnecting those connections as per the user's requirement
 Providing information for accounting purposes (e.g. metering calls)
 Time and attendance or Workforce Management clocks: we have many
varieties of clocks that suit every customer like electronic tags, barcode
badges, magnetic stripe cards, (hand, fingerprint, or facial), and touch
screens. We also have electrical time recorders, digital keyboard time
recorders and industrial time recorders.
 Online/Offline UPS: We have different UPS units either to protect a
single computer or to large units powering entire data centers, buildings
etc. Offline UPS offers surge protection and battery backup. Typical
protection time is 20 minutes and the switchover time is just 25
milliseconds. The Online UPS units provide 5–30 minutes of protection
time and the capacity expansion is for several hours. We have units
ranging from 500 watts or less to 10 kW.

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References
 The report has been made referring the information from
various sources and explanatory notes.
 Internet sources like wikipedia.com and google.com were also
referred for the same.
 Various materials available in the Instrumentation department
were also taken for reference work.