Conductor Manufacturing Process in Detail
Layout of conductor manufacturing plant:
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Established in 2008.
Location: Transrail Lighting Limited, Khanvel Road, Udhwa, Silvassa, India.
Section- A
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Aluminum Ingot
Melting & Holding Furness - Ingots into the pool
Casting & Rolling Mills
Rod preparation
Section- B
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Drawing strands
High-Speed Skip & Multi Stranding
Annealing
Coating ( In case of cable/ Optional)
Winding & Rewinding process
Quality Testing:
Conductor Manufacturing Process:
a. Aluminum Ingot:
 The raw aluminium comes in the form of block from vendars like Bharat Aluminium Co.
Ltd.
 Normal 95% purity & T-type 99.5% purity.
 1 MT rate 200 Rs/ Kg.
 Pre- material purity test using Spectrometer.
 Material requirements 50 MT- 80MT / Day.
b.
b. Melting & Holding Furness - Ingots into the pool
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Holding furness – 680 deg C (+/- 15 Deg c)
Chemical- Silica (0.08%), magnesium (0.52%) for alloy.
Cleaning of furness done regularly after every 4 month for 4-5 days.
Figure: 4. Ingots are heated in the Melting Furnas.
c. Scrap management
Scrap management is crucial to minimize waste, optimize production efficiency, and
reduce costs. Here are some key considerations for scrap management in a conductor
plant:
 Implement a system to segregate different types of scrap based on their composition
and characteristics. This allows for easier identification, sorting, and appropriate
disposal or recycling of specific materials.
 Establish a sorting area or facility where collected scrap can be further categorized
based on its potential for reusability or recyclability. Separate recyclable materials such
as aluminum or copper from other waste materials like steel wires, plastic reels, or
paper packaging.
 This can involve optimizing cutting or manufacturing processes, improving material
handling techniques, and training employees on waste reduction best practices.
 By implementing effective scrap management practices in a conductor plant, you can
minimize waste, optimize material usage, reduce environmental impact, and enhance
overall operational efficiency.
Figure: 3. Al rod & the spliced conductor pieces from the site are assembled here in the scrap yard.
d. Casting & Rolling Mills
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The manufacturing process of bare overhead conductors begins with casting. Typically,
aluminum or aluminum alloy rods are cast into the desired shape and size. The molten
metal is poured into molds, which are designed to give the conductor its specific crosssectional shape. The casting process ensures the initial formation of the conductor
before further processing.
Water is used for cooling has 80-85 deg c temperature.
The casting process is essential for ensuring the purity and integrity of the aluminum
material, as any impurities or defects can significantly affect the performance and
lifespan of the conductor.
Figure: 4. The casting bar coming out of the casting wheel.
e. Rod preparation
After the casting process, the solidified
conductors are further processed through
drawing. Drawing involves pulling the cast
conductor through a series of dies to
reduce its diameter while increasing its
length. The wire rods obtained from the
drawing process are then wound onto
spools in preparation for the next stage.
Figure: 5. The casting bar is under the process of rod formation.
Figure: 6. The rod is spooled to settle until the QC for proceeding next process.
f.
Drawing strands
Drawing is essential for refining the
material's grain structure and improving its
mechanical properties, such as tensile
strength and conductivity. The wire rods
obtained from the drawing process are
then wound onto spools in preparation for
the next stage.
The Rod is then further processed by
drawing a wire. And then again involves
pulling the rod through a series of dies to
reduce its diameter while increasing its
length to the wire.
Figure: 7. The strands/ wire are spooled in the small bobbins.
g. High-Speed Skip & Multi Stranding
Figure: 8. The stranding of the first layer of the conductor is in the process.
h. Annealing
Annealing bare conductors, specifically for aluminum or copper conductors used in
electrical applications, is a crucial step in the manufacturing process. The annealing
process helps improve the electrical conductivity, ductility, and mechanical properties
of the conductors. Proper annealing of bare conductors is crucial to ensure the desired
electrical and mechanical properties. It is typically performed before the conductors
are further processed, such as stranding or insulating, to optimize their performance
in power transmission and distribution systems.
The annealing of bare conductors typically involves the following steps:
 Coil Preparation: The bare conductors are often manufactured in large coils.
Before annealing, the coils are prepared by straightening and cleaning the
conductors to ensure uniform heat distribution during the process.
 Heating: The coils of bare conductors are heated to a specific temperature
that is determined based on the material and the desired properties. For
aluminum conductors, the temperature is usually between 250 to 400°C
(482 to 752°F), while for copper conductors, it is typically between 200 to
300°C (392 to 572°F).
 Soaking: Once the conductors reach the annealing temperature, they are
held at that temperature for a specific period. This duration, known as the
soaking time, allows the heat to penetrate the entire cross-section of the
conductors, ensuring thorough annealing.
 Controlled Cooling: After the soaking period, the conductors slowly cooled
down to room temperature. The cooling rate is carefully controlled to avoid
any rapid temperature changes that could lead to thermal stress or
distortion in the conductors.
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Coating (Optional):
j.
Winding & Rewinding process
Once the conductors have been drawn to the required dimensions, they are wound
onto large spools or drums. Winding is done carefully to prevent any damage or
distortion to the conductor.
Winding is the process of taking the wire rods obtained from drawing and winding
them onto large drums. This process is performed with precision to ensure the
proper alignment and tension of the conductors. Winding also helps in eliminating
any remaining internal stresses and improving the mechanical strength of the
conductor. The wound conductors are then ready for the final stage of
manufacturing, which involves quality-type tests.
The spools or drums can hold a significant length of the conductor, making it easier
to transport and handle during installation. The re-winding is the same process as
winding but sometimes we need to rewind the drum for a visual check and ensure
the quality type tests.