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I.INTRODUCTION

TRACO CABLE COMPANY, a Premier Kerala Government

Company, commenced operations in the year 1964, manufacturing high quality Electric
Cables and Wires in Technical Collaboration with M/s. Kelsey Engineering Co. Ltd.,
Canada. Since then TRACO has been in the forefront in meeting the needs of Public Sector
Undertakings in India like Railways, Electricity Boards of various states in the country and
others for AAC/ACSR, Power and Signalling Cables.
One of India's most sought after Paper Insulated Lead Sheathed
Telecommunication Cables were produced by TRACO in collaboration with Hindustan
Cables, West Bengal under an agreement signed in 1974 until the liberalisation of Licencing
policy in the country, TRACO was one of the two manufactures of Telephone Cables in
India and the only one in the whole of South India. With the progress in Cable Technology,
Paper Insulated Cables gave way to the much more sophisticated Jelly Filled Telephone
cables which are superbly suited for communications. TRACO was one among those who
first preceived the opportunities inherent in this new development. It soon went into
Technical collaboration with M/s. General Cables Inc. , USA, world leaders in the
Communication cable field and manufactured them in India to exacting standards.
TRACO's new range of self support Aerial Cables connect people aerially at the same time ,
economically. They are manufactured to both national and international standards .
TRACO has developed Aerially Bunched Cables for LT Overhead lines also . They are
polythene Insulated Aluminium Cables of specification : REC Specification No.s2/1984
and have a rated voltage of 1.1 K V. This type of cables help in reducing the power
interruptions to the barest minimum level possible. Many of the advanced countries are all
ready switching over to these cables from the bare counter system.

II.COMPANY PRODUCTS
I) ACSR/ AAAC/AAC (overhead conductors up to 61 strands)

All Aluminum Conductors (AAC) as per IS: 398 for power distribution

All Alloy Aluminum Conductors (AAAC) as per IS : 398 for power distribution

Aluminum Conductors with Steel Reinforcement (ACSR) as per IS: 398 for power
distribution and transmission.

II) POWER CABLES

Copper and Aluminum conductors up to 1100/1500 volts) and Control cables/
signaling cables (copper conductors up to 37 conductors) as per IS: 1554 with PVC
insulation.
III) JELLY FILLED TELEPHONE CABLES
(Unarmored and Armored 5 pairs to 1600 pairs) as per BSNL specification.
IV) AERIAL CABLES
(Copper conductors overhead telephone cables up to 20 pairs) as per BSNL specification.
V) DROP WIRE
(Copper conductor single pair telephone cable) as per BSNL specification.
VI) WEATHER PROOF CABLES
(Aluminium conductor, PVC insulated single/ multi core) for power service connection as
per IS: 694 specifications.

VII) HOUSE WIRING AND FLEXIBLE CABLES

(Copper conductor up to 128 strands) as per IS: 694 specifications.
VIII) RAILWAY SIGNALING CABLES
Signaling Cables - Used by Railways. PVC insulated & sheathed armored/unarmored
Copper cables. 1100 V. Grade. Spec: Indian Railway Specification No: S63 - 89 for PVC
insulated cables for Railway Signaling.
IX) POWER CABLE WITH ALUMINIUM CONDUCTOR
PVC insulated and sheathed armored/unarmored Aluminum power cables 1100 V. Grade.
Spec: IS: 1554

EXISTING AND NEW PRODUCTS

Aluminium conductor steel Reinforced cables
Weather proofing cable
Railway signaling cable

All Aluminium Alloy Conductors

As Al-Mg-Si Alloy is joined our conductor family, we are growing beyond Steel. TRACO
has added All Aluminium Alloy Conductors(AAAC) to its product range and joined the
energy conservation moment. Some of the salient features which make All Aluminium
Alloy Conductors (AAAC) markedly superior to ACSR are as follows:

1. High strength/weight ration: 21 to 26% lighter as compared to ACSR . Reduction of

tension is 21 to 23% and hence lighter towers would be satisfactory- saving in cost
would be greater.
2. High Electrical Conductivity:- Conductivity is 6% to 11% higher than the
corresponding ACSR-Lower AC resistance and hence, considerable decrease in line
losses.
3. Good corrosion Resistance:- Usage of AAAC in the coastal area is of great
significance.
4. Great Abrasion and Creap Resistance:- Abration resistance of alloy stands is more
than four times that of E.C.G. Grade Aluminium. Overall strength will not change in
case of repetition short duration short circuits.
5. High conductor Metal Efficiency:- Metal efficiency of Aluminium Alloy wire is 126
whereas that of EC Grade Aluminium is only 82.
6. Thermal Expansion:- Along with the rise and fall of temperature the sag increases
osr decreases to throughout the conductor.
7. Connectability :- Superior to ACSR - Greater torque can be applied without concern
for the cold flow beneath the conductor.

Role Of Aluminium
There are some great reasons because in numerous countries aluminium has taken the place
of copper for main conductor material of all components of the transmission and
distribution systems.
Aluminium is much lighter than copper. The density of aluminium is about 30 % that of
copper. Especially in overhead line construction this factor is very important because heavy
conductors lead to heavy and expensive pole structures. Handling and transportation of
aluminium conductors and cables are also easier compared with heavy copper conductors
and cables. The lightness of aluminium gives advantages in many ways :

Aluminium is the most common metal in the earth surface - its amount is about 8 %. Today
copper are limited and diminishing so the price of copper has been high and rising. The
price of aluminium was low and rather steady state for years, but some rising can be noticed
in it, too. Because of lightness of aluminium, the price of aluminium conductors and cables
are clearly smaller than those of copper conductors and cables.
Long-distance overhead conductors use aluminium in first choice to copper - the inferior
electrical conductivity being more than compensated by the lower density and cost. In
composite steel-Al Cables, the steel carries largely or all of the mechanical load, and the Al
the electrical current. Aluminium is frequently now used throughout, serving both electrical
and mechanical purposes.

Aluminium is about a third the weight than equal volume of copper, steel or brass.

Aluminium can supported heavy loads and heavy pressures.

The strength when alloyed approaches that of steel.

Corrosion resistance - The creation of a microscopic film of aluminium oxide on the surface
of the metal protects it against corrosion and also makes a good insulation.
Electrical conductivity - Aluminium has two times the conductivity of an equal weight of
copper.
Resilience and Flexibility
Thermal conductivity - Aluminium distribute heat and cooling energy consistently and
rapidly.
Thermal Ductility - Aluminium is uncomplicated to cold work and manufacture.
Mixability - Can be simply modified by adding alloys to make a final metal that is
essentially flexible, conductive or pliable than aluminium alone.

Cost efficiency low cost processing

III. PRODUCTION DEPARTMENT

The production department is concerned with the production of ACSR and weather proof
cables. The main raw materials used in production are aluminium conductor (9.5mm) and
steel rod. Now companys yearly production depends on the order. Capacity is 1500 metrics
tons per year.

1.PRODUCTION PROCESS OF ACSR CABLES

ACSR cables means aluminium conductor steel reinforced cables. Main raw material for
ACSR cables are aluminium and steel. Aluminium cables are of 9.5 mm diameter .The
production includes the following process:
(a)wire drawing process
(b)steel rewinding
(c)stranding
First step for production of ACSR cables is to pass aluminium wires through a rod break
down machine so that we could get aluminium wire at required size. In this machine 13 sets
of dyes are placed,such that the 1st dye has the largest diameter and it goes on reducing.And
the last dye will be of the diameter which is the required size of our cable.These aluminium
wires should rebound to a rebound bobbin.
Next step for production is rewinding of steel through a steel rewinding machine. After
rewinding, steel should be rewind to a rebound bobbin. Final but most important step of
ACSR production is placing these rebound bobbins in tubular stranders.Tubular strander is
a machine used for stranding of cables. Ratio regarding number of rewound bobbins to be

placed in tabular stranders is that there will be six aluminium bobbins and one steel bobbin.
When the power is on the six aluminium cables are twisted to the steel cable.
The final product ACSR is come out and these ACSR cables are rebound in a wooden
drum. Later ACSR cables should be transferred to quality assurance for final inspection.
After final inspection and testing the tested OK cables are handed over to stores non
conformities' identified during each stage of inspection shall be recorded in the non
conformity report and handed over to the shift in charge(production) for appropriate action.
The company follow shift working and it has three shifts and these shifts have its own
target. KUNDHAH is a large size ACSR.here 7 steel wires are stranded with 42
aluminium wires in a 54 bobbil strand,which is the machine used to strand 42 aluminium
wires(3 layers).The size of steel is 1.98 mm and that of aluminium is 3.5 mm.
1.1 TYPES OF ACSR CABLES
1. Squirrel - 6+1 (Includes 6 aluminium wire and 1 steel wire having diameter of 2.11
mm)
Specification: 1+6/2.11
2. Weasel-6+1 (Includes 6 aluminium wire and 1 steel wire having diameter of
2.59mm)
Specification: 1+6/2.59
3. Rabbit - 6+1 (Includes 6 aluminium wire and 1 steel wire having diameter of
3.55 mm)
Specification: 1+6/3.55
4. Racoon - 6+1 (Includes 6 aluminium wire and 1 steel wire having diameter of
4.09 mm)

Specification: 1+6/4.09
SUPPLIERS -The major suppliers of raw materials for ACSR cables are:
Aluminium
Nalco
Balco
Hindalco
Steel
Tata
Aradhya

1.2 PROCESS FLOWCHART OF ACSR CONDUCTOR

PRODUCTON

Incoming material

Steel R/W machine

stores

RBC M/C

Stranded tubular rod

bins

packing

Final inspection

Dispatch

RM lab

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2.MANUFACTURE OF PVC SHEATHED WEATHER PROOF CABLES

FOLLOWING ARE THE STEPS IN THE MANUFACTURING PROCESS OF
WEATHER PROOF CABLES:
Step1: Reduce the size of aluminium to the required size using RBD (Rod Break Down).
Step2: With the help of LP100 machine sheath the aluminium conductors with coloured
PVC i.e. red and black.
Step3: Then these two

are sheathed with black coloured PVC with the help of

extruder.extruder is the machine used to give insulation.(pvc granules are given to the
extruder)
Aluminiumandpvcaretherawmaterialsused.specification 2*6 sq mm
.conductor size 2.75=approx 2.8

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IV. Conclusion
TRACO CABLE COMPANY, a Premier Kerala Government Company does not make any
harmfulness to the surroundings. The plant runs round the clock with each department
playing crucial roles in its smooth running and together they maintain the market leadership
meeting global standards.
The unit offers vast employment opportunities for skilled labourers in the locality and has
been the so ever since it started. The HR department of the company takes excellent care of
its employees with various schemes, medical care assistances, financial aid and provisions
for assistance in developing basic amenities. The company meets all the statutory
requirements for the betterment of the Employees. The two trade unions ensure that the
rights of all workers are fulfilled and demands are met.
Thus, the organizational study conducted at Traco Cable Company, helped to throw
knowledge and insight into the workings of the organization. It helped me to familiarize
with different departments in the organization and their functionings. This study helped me
to understand the relationship between management principles and practical applications. It
also helped me to know the threats and opportunities faced by the company and the
industry. I was also able to maintain an amiable relationship with the employees as well as
with the managers. This study was a great experience for me and I am proud that I was able
to do my organizational study at Indias no.1 Cable manufacturer.