RAMSARUP INDUSTRIES

A

Seminar Report on

PRACTICAL TRAINING TAKEN AT

RAMSARUP INDUSTRIES LTD., KOLKATA

submitted in partial fulfillment of

requirements for the degree

of

B.TECH.

MECHANICAL ENGINEERING

Submitted by

Imran Younus(09EGJME025)

Submitted to

Mr. Sunil SharmaAssistant Professor

DEPARTMENT OF MECHANICAL ENGINEERINGGlobal Institute Of Technology

Sitapura, Jaipur-3020222012-13

ii

Global Institute Of Technology

DEPARTMENT OF MECHANICAL ENGINEERING

JAIPUR (RAJASTHAN)-302022

CERTIFICATE

This is to certify that this seminar report on Practical Training taken at “Ramsarup

Nirmaan Wires” of “Ramsarup Industries Ltd., Kolkata” is submitted by IMRAN

YOUNUS and Univ. Roll. No. 09EGJME025 to the Department of Mechanical

Engineering, Global Institute of Technology, Jaipur for the award of the degree in

B.Tech. Mechanical Engineering is a bonafide record of work carried out by him.

The contents of this Seminar Report in full or in parts have not been submitted to

any other Institute or University for the award of any degree or diploma.

Mr. Sunil Sharma Mrs. Bhavana Mathur

Seminar Coordinator Head of Department

iii

Acknowledgement

I find myself very fortunate to have undergone my Industrial Training from

RAMSARUP INDUSTRIES LTD. at Ramsarup Nirmaan Wires, Durgapur.

The persons of my department have extended their warm and helping hand. I am

very fortunate to get a chance to know & understand the processes undergone in the

Repairing Department.

It was a golden opportunity for me to get an exposure in such a renowned company,

where discipline and quality are main motto.

I am also very thankful to the shop supervisors and workers for being kind and give

helping hand in gaining the knowledge.

I am also thankful to the management board of my college who has included this

type of training to impart practical knowledge by exposing ourselves to the industry.

I hope this training, which is the fruit of long dedicated hours of efforts & consistent

dedication, will also be appreciated. No work can be perfect, without ample

guidance. I would like to express my deep gratitude & heartiest thank to my Head of

the Department of Mechanical Engineering Mrs. Bhavana Mathur and the Training

Seminar Coordinators Mr. Sunil Sharma & Mr. Saket Sharma who infused me

with the spirit to work upon challenging field, which has its inception in such a time

when there is a dire need for new orientation.

Imran Younus

09EGJME025

iv

CONTENTS

Chapter No.

TitlePage No.

1. INTRODUCTION 01

1.1. Profile 01

1.1.1.Ramsarup Industrial Corporation

03

1.1.2.Ramsarup Nirmaan Wires

04

1.1.3.Ramsarup Lohh Udyog

05

1.1.4.Ramsarup Infrastructure

05

1.1.5.Ramsarup Utpadak

06

1.1.6.Ramsarup Vidyut

07

2. RAMSARUP NIRMAAN WIRES 08

2.1. Wire Rod 09

2.2. Surface Treatment 09

2.3. Wire Drawing 09

2.4. Stranding 09

2.4.1. Advantages of Stranded Wires 09

2.4.2. Disadvantages of Stranded Wires 10

3. SURFACE TREATMENT 11

3.1. Process 12

3.2. Disadvantages 13

3.3. Waste Products 13

v

3.4. Alternatives 13

3.5. Pickling of Steels 14

3.6. Phosphoric Acid 14

3.6.1. Rust Removal 14

4. WIRE DRAWING 16

4.1. Process 16

4.2. Lubrication 19

4.3. Mechanical Properties 19

4.4. Drawing Dies 20

5. STRANDING 21

5.1. Number of Strands 21

6. PACKING 23

6.1. Seaworthy Packing Procedure 23

6.1.1. Vendor’s Obligation and Responsibilities 24

6.1.2. Steel Structure and Plates 25

CONCLUSION 26

REFERENCES 27

vi

LIST OF FIGURES

Figure No. Title Page No.

1.1 Customer Base 02

1.2 Ramsarup Industrial Corporation 03

1.3 Ramsarup Nirmaan Wires 04

1.4 Ramsarup Lohh Udyog 05

1.5 Ramsarup Infrastructure 06

1.6 Ramsarup Utpadak 06

1.7 Ramsarup Vidyut 07

2.1 Manufacturing Process 08

3.1 Pickling Process 11

4.1 Wire Drawing Concept 16

4.2 High Speed Wire Drawing Machine 18

4.3 Carbide Wire Drawing Die 20

6.1 Seaworthy Packing 23

vii

CHAPTER 1

INTRODUCTION

RAMSARUP GROUP was founded in 1966 and has grown substantially in last of the

decades. It is one of the largest manufacturer of steel wires and a leading player in

TMT manufacturing in Eastern India. The infrastructure division is involved in power

transmission and distribution, bridge-building and laying of sewerage and water

pipelines. It is one of the fastest growing groups catering to the power and

infrastructure sectors in India and they aim to consolidate the position by initiating

steps towards organic and inorganic growth.

In keeping with the goal to be one of the most integrated players in the steel sector,

they have put up an integrated steel plant at Kharagpur to act as a feeder for the

existing wire and TMT units.

The Group turnover was over Rs. 2000 Crores (US $ 385 Millions) in 2008-09 with a

net worth of over Rs. 450 Crores (US $ 82 Millions).

They provide themselves on the fact that brand Ramsarup is highly regarded for its

consistent quality.

At Ramsarup, they believe that sustainability is key; Cornerstone of the dream is to

emerge as one of the most profitably and environmentally sustainable enterprises with

complete integration from iron ore to transmission lines.

1.1 Profile:

Ramsarup Industries Limited was incorporated in 1979. 

It is a profit making and dividend paying company. 

The company is listed at National Stock Exchange, Bombay Stock Exchange

and Calcutta Stock Exchange.

1

The company is engaged in manufacturing of wires, TMT bars and steel.

Also engaged in infrastructure development of India.

The head office is in Kolkata Operates through its only office at Kolkata and

the plants are at Kalyani, Durgapur, Shyamnagar & Kharagpur.  The products

are sold from Kutch to Kamrup and Kashmir to Kanyakumari.

The company has six units :-

a) Ramsarup Industrial Corporation

b) Ramsarup Nirmaan Wires

c) Ramsarup Lohh Udyog

d) Ramsarup Infrastructure

e) Ramsarup Utpadak

f) Ramsarup Vidyut

Broad customer base both in terms of segment & geographical spread.

Power is the major thrust area, with almost 40% of the top line coming from

the power sector.

Fig. 1.1 Customer Base

2

1.1.1 Ramsarup Industrial Corporation:

Commenced its manufacturing activities in 1966.

Installed capacity of steel wires - 1, 97,000 MTs (coated and uncoated).

An ISO 9001: 2000 Unit.

One of the largest manufacturer of steel wires in India. Vast range of G I

Wires from 4 guage to 24 guage (26 different sizes).

Fig. 1.2 Ramsarup Industrial Corporation

Un-interrupted production since inception.

Registered with PGCIL, APDRP Projects, and Electricity Boards etc.

Building new capacities to tap the opportunities in the power transmission

and distribution sector in India.

Selling material under its brand "RAMSARUP".

Exporting its products to several countries.

3

1.1.2 Ramsarup Nirmaan Wires:

Started in 2008. 

Manufacturing Low Relaxation Pre-stressed Concrete (LRPC) Strand,

Single Line LRPC Wires & other speciality wires. 

First in India to manufacture Single Line LRPC Wires. 

State of the art unit with complete automated machines imported from GCR,

Italy.

Installed Capacity: 54,000 MTPA (1st Phase) and 30,000 MTPA (2nd Phase).

47,000 MTPA 3rd Phase under implementation. 

The LRPC wires manufactured by Ramsarup confirm to global standards and

are utilized in construction of pre-stressed girders for Roads River & railway

bridges and flyovers, pre-stressed atomic rector domes, slabs, silos hangers,

aqueducts, high-rise buildings and railway sleepers.

Fig. 1.3 Ramsarup Nirmaan Wires

3rd phase comprises of plating line to produce hose wire, staple wire,

electroplated wire, rope wire, annealed wire etc.

An ISO 9001:2000 company.

Working towards ISO 14000:2004 & 18001:2007. 

Products made as per IS 14268/1995, JIS 3536, JIS 3536, ASTM A 416-98a,

BIS 589 and also as per clients specification.

4

Selling material under its brand "RAMSARUP". 

Exporting its products to several countries around the globe.

1.1.3 Ramsarup Lohh Udyog:

Formed as a separate company in the year 2004. 

Was merged with Ramsarup Industries Limited in the year 2008. 

The unit has been put up to complete the integration mission of Ramsarup i.e.

from iron ore mines to transmission lines. 

Fig. 1.4 Ramsarup Lohh Udyog

Will feed the wire units and TMT unit of Ramsarup Industries Limited. 

Total land area – 325 acres.

1.1.4 Ramsarup Infrastructure:

Since large part of products used in Transmission & Distribution work like

Cables, Conductors, Poles, Earth Wires, Stay Wires requires steel wires to be

used directly/ indirectly, we decided to enter into this business. Further, It is

already registered with most of the electricity boards of India it was rationale

decision to extend The relationship. It also helped us in increasing The

customer base for wires and also in reducing The cost of purchases of

Conductors & Cables due to The strong presence in wire business 

5

Fig. 1.5 Ramsarup Infrastructure

The strong civil & design/ drawing team encouraged as to get into other civil

related infra projects like bridges, sewerage and water pipelines

Joint venture partners also provided us with required expertise

1.1.5 Ramsarup Utpadak:

Ramsarup Industries Limited took over the Steel Division of Nicco

Corporation Ltd in August 2002. The above unit is engaged in manufacturing

of TMT Bars, Wire Rods and Steel Wires.

Installed capacity of TMT Bars (Re-inforcement & Debars) - 167000 MTs &

Steel Wires - 36000 Mts.

An ISO 9001:2000 unit.

Fig. 1.6 Ramsarup Utpadak

Only producer in India to provide complete range of 8mm to 40mm Bars

using thermal Technology.

6

Supplier to large projects and companies and registered with Contractor of

NHPC, NTPC, CPWD, Nuclear Power Corporation etc.

Selling material under its brand "RAMSARUP".

1.1.6 Ramsarup Vidyut:

The company has installed 3 nos of Wind Turbine Generators of capacity 1.25

mw each at Dist Dhule in Maharashtra, India.

Fig. 1.7 Ramsarup Vidyut

7

CHAPTER 2

RAMSARUP NIRMAAN WIRES

It is one of the six units of Ramsarup Industries Ltd. It is engaged in Manufacturing

Low Relaxation Pre-stressed Concrete (LRPC) strand, Single Line LRPC Wires &

other speciality wires. It is first in India to manufacture Single Line LRPC Wires. It

is situated in Durgapur, West Bengal (INDIA).

The company manufacture LRPC Strands/Wires by using the manufacturing process

as given below:

Fig. 2.1

Manufacturing Process

2.1 Wire Rod:

8

Wire rod is a rolled alloy or nonalloy steel product, produced from a semi (e.g.

bloom) and having a round, rectangular or other cross-section. Particularly fine

cross-sections may be achieved by subsequent cold forming (drawing). Wire rod is

wound into coils and transported in this form.

2.2 Surface Treatment:

Surface treatment is a broad range of industrial processes that alter the surface of a

manufactured item to achieve a certain property. It is a metal surface treatment used

to remove impurities, such as stains, inorganic contaminant

rust or scale from ferrous metals, copper and aluminium alloys. A solution called

pickle liquor, which contains strong acids, is used to remove the surface impurities. It

is commonly used to de-scale or clean steel in various steelmaking processes.

2.3 Wire Drawing:

Wire drawing is a metalworking process used to reduce the cross-section of a wire by

pulling the wire through a single, or series of, drawing die(s). There are many

applications for wire drawing, including electrical wiring, cables, tension-loaded

structural components, springs, paper clips, spokes for wheels, and stringed musical

instruments.

2.4 Stranding:

Stranded wire is helpful, especially in larger wire sizes to enable more flexibility in

routing of the wire and offers more durability for applications where vibration and

occasional movement of the wire could cause breakage of a stiffer solid wire.

2.4.1 Advantages of Stranded Wire:

1. More flexible for routing

2. More durable for vibration and infrequent movement.

 2.4.2 Disadvantages of Stranded Wire:

9

1. Larger size.

2. More costly especially as stranding increases as more processing is required

to manufacture it.

10

CHAPTER 3

SURFACE TREATMENT

Surface treatment is a broad range of industrial processes that alter the surface of a

manufactured item to achieve a certain property. Treatment processes may be

employed to: improve appearance, adhesion or weldability, solderability, corrosion

resistance, tarnish resistance, chemical resistance, wear resistance, hardness, modify

electrical conductivity, remove burrs and other surface flaws, and control the surface

friction. In limited cases some of these techniques can be used to restore original

dimensions to salvage or repair an item.

Fig. 3.1 Pickling Process

11

Pickling is a metal surface treatment used to remove impurities, such as stains,

inorganic contaimina rust or scale from ferrous metals, copper and aluminum alloys.

A solution called pickle liquor, which contains strong acids, is used to remove the

surface impurities. It is commonly used to descale or clean steel in

various steelmaking processes.

3.1 Process:

Many hot working processes and other processes that occur at high temperatures

leave a discoloring oxide layer or scale on the surface. In order to remove the scale

the workpiece is dipped into a vat of pickle liquor.

The primary acid used is hydrochloric acid, although sulphuric acid was previously

more common. Hydrochloric acid is more expensive than sulphuric acid, but it

pickles much faster while minimizing base metal loss. The speed is a requirement for

integration in automatic steel mills that run production at high speed; speeds as high

as 800 ft/min (≈243 metres/min) have been reported.

Carbon steels, with an alloy content less than or equal to 6%, are often pickled in

hydrochloric or sulphuric acid. Steels with an alloy content greater than 6% must be

pickled in two steps and other acids are used, such

as phosphoric, nitric and hydrofluoric acid. Rust- and acid-resistant chromium-nickel

steels are pickled in a bath of hydrochloric and nitric acid. Most copper alloys are

pickled in dilute sulphuric acid, but brass is pickled in concentrated sulphuric and

nitric acid mixed with sodium chloride and soot.

In jewellery making, pickling is used to remove the oxidation layer from copper

surfaces, which occurs after heating. A diluted sulphuric acid pickling bath is used.[3]

Sheet steel that undergoes acid pickling will oxidize (rust) when exposed to

atmospheric conditions of moderately high humidity. For this reason, a thin film of

oil or similar waterproof coating is applied to create a barrier to moisture in the air.

This oil film must later be removed for many fabrication, plating or painting

processes.

12

3.2 Disadvantages:

Acid cleaning has limitations in that it is difficult to handle because of its

corrosiveness, and it is not applicable to all steels. Hydrogen embrittlement becomes

a problem for some alloys and high-carbon steels. The hydrogen from the acid reacts

with the surface and makes it brittle and causes cracks. Because of its high reactance

to treatable steels, acid concentrations and solution temperatures must be kept under

control to assure desired pickling rates.

3.3 Waste products:

Pickling sludge is the waste product from pickling, and includes acidic rinse waters,

metallic salts and waste acid. Spent pickle liquor is considered a hazardous waste by

the EPA. Pickle sludge from steel processes is usually neutralized with lime and

disposed of in a landfill. After neutralization the EPA no longer deems it a hazardous

waste. The lime neutralization process raises the pH of the spent acid and

makes heavy metals in the sludge less likely to leach into the environment. Since the

1960s, hydrochloric pickling sludge is often treated in a hydrochloric acid

regeneration system, which recovers some of the hydrochloric acid and ferric oxide.

The rest must still be neutralized and disposed of in landfills. The by-products of

nitric acid pickling are marketable to other industries, such as fertilizer processors.

3.4 Alternatives:

Smooth clean surface (SCS) and eco pickled surface (EPS) are more recent

alternatives. In the SCS process, surface oxidation is removed using an engineered

abrasive and the process leaves the surface resistant to subsequent oxidation without

the need for oil film or other protective coating. EPS is a more direct replacement for

acid pickling. Acid pickling relies on chemical reactions while EPS uses mechanical

means. The EPS process is considered "environmentally friendly" compared with

acid pickling and it imparts to carbon steel a high degree of rust resistance,

eliminating the need to apply the oil coating that serves as a barrier to oxidation for

acid-pickled carbon steel.

13

3.5 Pickling of steel:

One of the most important applications of hydrochloric acid is in the pickling of

steel, to remove rust or iron oxide scale from iron or steel before subsequent

processing, such as extrusion, rolling, galvanizing, and other techniques. Technical

quality HCl at typically 18% concentration is the most commonly used pickling

agent for the pickling of carbon steel grades.

Fe2O3 + Fe + 6 HCl → 3 FeCl2 + 3 H2O

The spent acid has long been re-used as iron (II) chloride (also known as ferrous

chloride) solutions, but high heavy-metal levels in the pickling liquor have decreased

this practice.

The steel pickling industry has developed hydrochloric acid regeneration processes,

such as the spray roaster or the fluidized bed HCl regeneration process, which allow

the recovery of HCl from spent pickling liquor. The most common regeneration

process is the pyrohydrolysis process, applying the following formula:

4 FeCl2 + 4 H2O + O2 → 8 HCl+ 2 Fe2O3

By recuperation of the spent acid, a closed acid loop is established. The iron (III)

oxide by-product of the regeneration process is valuable, used in a variety of

secondary industries.

3.6 Phosphoric acid:

3.6.1 Rust removal:

Phosphoric acid may be used as a "rust converter", by direct application to rusted

iron, steel tools, or surfaces. The phosphoric acid converts reddish-brown iron (III)

oxide, Fe2O3 (rust) to black ferric phosphate, FePO4.

"Rust converter" is sometimes a greenish liquid suitable for dipping (in the same sort

of acid bath as is used for pickling metal), but it is more often formulated as a gel,

commonly called naval jelly. It is sometimes sold under other names, such as "rust

remover" or "rust killer". As a thick gel, it may be applied to sloping, vertical, or

even overhead surfaces.

14

After treatment, the black ferric-phosphate coating can be scrubbed off, leaving a

fresh metal surface. Multiple applications of phosphoric acid may be required to

remove all rust. The black phosphate coating can also be left in place, where it will

provide moderate further corrosion resistance.

15

CHAPTER 4

WIRE DRAWING

Wire drawing is a metalworking process used to reduce the cross-section of

a wire by pulling the wire through a single, or series of, drawing die(s). There are

many applications for wire drawing, including electrical wiring, cables, tension-

loaded structural components, springs, paper clips, spokes for wheels, and stringed

musical instruments. Although similar in process, drawing is different

from extrusion, because in drawing the wire is pulled, rather than pushed, through

the die. Drawing is usually performed at room temperature, thus classified as a cold

working process, but it may be performed at elevated temperatures for large wires to

reduce forces. More recently drawing has been used with molten glass to produce

high quality optical fibres.

4.1 Process:

Fig. 4.1 Wire drawing concept

The wire drawing process is quite simple in concept. The wire is prepared by

shrinking the beginning of it, by hammering, filing, rolling or swaging, so that it will

fit through the die; the wire is then pulled through the die. As the wire is pulled

through the die, its volume remains the same, so as the diameter decreases, the length

16

increases. Usually the wire will require more than one draw, through successively

smaller dies, to reach the desired size. The American wire gauge scale is based on

this. This can be done on a small scale with a draw plate, or on a large commercial

scale using automated machinery. The process of wire drawing changes material

properties due to cold working.

The areal reductions of small wires are 15–25% and larger wires are 20–45%. Very

fine wires are usually drawn in bundles. In a bundle, the wires are separated by a

metal with similar properties, but with lower chemical resistance so that it can be

removed after drawing. If the reduction in diameter is greater than 50%, the process

may require annealing between the process of drawing the wire through the dies.

Commercial wire drawing usually starts with a coil of hot rolled 9 mm (0.35 in)

diameter wire. The surface is first treated to remove scales. It is then fed into either a

single block or continuous wire drawing machine.

Single block wire drawing machines include means for holding the dies accurately in

position and for drawing the wire steadily through the holes. The usual design

consists of a cast-iron bench or table having a bracket standing up to hold the die,

and a vertical drum which rotates and by coiling the wire around its surface pulls it

through the die, the coil of wire being stored upon another drum or "swift" which lies

behind the die and reels off the wire as fast as required. The wire drum or "block" is

provided with means for rapidly coupling or uncoupling it to its vertical shaft, so that

the motion of the wire may be stopped or started instantly. The block is also tapered,

so that the coil of wire may be easily slipped off upwards when finished. Before the

wire can be attached to the block, a sufficient length of it must be pulled through the

die; this is effected by a pair of gripping pincers on the end of a chain which is

wound around a revolving drum, so drawing the wire until enough can be coiled two

or three times on the block, where the end is secured by a small screw clamp or vice.

When the wire is on the block, it is set in motion and the wire is drawn steadily

through the die; it is very important that the block rotates evenly and that it runs true

and pulls the wire at a constant velocity, otherwise "snatching" occurs which will

weaken or even break the wire. The speeds at which wire is drawn vary greatly,

according to the material and the amount of reduction.

17

Continuous wire drawing machines differ from the single block machines in having a

series of dies through which the wire passes in a continuous manner. The difficulty

of feeding between each die is solved by introducing a block between each die. The

speeds of the blocks are increased successively, so that the elongation is taken up and

any slip compensated for. One of these machines may contain 3 to 12 dies.  The

operation of threading the wire through all the dies and around the blocks is termed

"stringing-up".

The arrangements for lubrication include a pump which floods the dies, and in many

cases also the bottom portions of the blocks run in lubricant.

Fig. 4.2 High Speed Wire Drawing Machine

Often intermediate anneals are required to counter the effects of cold working, and to

allow further drawing. A final anneal may also be used on the finished product to

maximize ductility and electrical conductivity.

An example of product produced in a continuous wire drawing machine is telephone

wire. It is drawn 20 to 30 times from hot rolled rod stock.

18

While round cross-sections dominate most drawing processes, non-circular cross-

sections are drawn. They are usually drawn when the cross-section is small and

quantities are too low to justify rolling. In these processes, a block or Turk's-head

machine are used.

4.2 Lubrication:

Lubrication in the drawing process is essential for maintaining good surface finish

and long die life. The following are different methods of lubrication:

Wet drawing: the dies and wire or rod are completely immersed in lubricant.

Dry drawing: the wire or rod passes through a container of lubricant which coats

the surface of the wire or rod.

Metal coating: the wire or rod is coated with a soft metal which acts as a solid

lubricant.

Ultrasonic vibration: the dies and mandrels are vibrated, which helps to reduce

forces and allow larger reductions per pass.

Various lubricants, such as oil, are employed. Another lubrication method is to

immerse the wire in a copper (II) sulphate solution, such that a film of copper is

deposited which forms a kind of lubricant. In some classes of wire the copper is left

after the final drawing to serve as a preventive of rust or to allow easy soldering. The

best example of copper coated wire is in MIG wire or Co2 wire used in welding. The

steel wires are copper coated for lubrication.

4.3 Mechanical Properties:

The strength-enhancing effect of wire drawing can be substantial. The highest grule

strengths available on any steel have been recorded on small-diameter cold-drawn

austenitic stainless wire. Tensile strength can be as high as 400 ksi (3760 MPa).

19

4.4 Drawing dies:

Fig. 4.3 Carbide wire drawing die

Drawing dies are typically made of tool steel, tungsten carbide, or diamond, with

tungsten carbide and manufactured diamond being the most common. For drawing

very fine wire a single crystal diamond die is used. For hot drawing, cast-steel dies

are used. For steel wire drawing, a tungsten carbide die is used. The dies are placed

in a steel casing, which backs the die and allow for easy die changes. Die angles

usually range from 6 – 15 ° and each die has at least 2 different angles: the entering

angle and approach angle. Wire dies usually are used with power as to pull the wire

through them. There are coils of wire on either end of the die which pull and roll up

the wire with a reduced diameter.

20

CHAPTER 5

STRANDING

In the so-called cross lay strands, the wires of the different layers cross each other. In

the mostly used parallel lay strands, the lay length of all the wire layers is equal and

the wires of any two superimposed layers are parallel, resulting in linear contact. The

wire of the outer layer is supported by two wires of the inner layer. These wires are

neighbours along the whole length of the strand. Parallel lay strands are made in one

operation. The endurance of wire ropes with this kind of strand is always much

greater than of those (seldom used) with cross lay strands. Parallel lay strands with

two wire layers have the construction Filler, Seale or Warrington.

5.1 Number of strands

The more individual wire strands in a wire bundle, the more flexible, kink-resistant,

break-resistant, and stronger the wire is. But more strands cost more.

The lowest number of strands is 7: one in the middle, 6 surrounding it.

The next level up is 19, which is another layer of 12 strands on top of the 7. After

that the number varies, but 37 and 49 are common, then in the 70 to 100 range (the

number is no longer exact). Even larger numbers than that are typically found only in

very large wires.

For application where the wire moves, 19 is the lowest that should be used (7 should

only be used in applications where the wire is placed and then does not move), and

49 is much better. For applications with constant repeated movement, such as

assembly robots and headphone wires, 70 to 100 is mandatory.

For applications that need even more flexibility (welding is the usual example, but

also any need to move wire in tight areas), even more strands are used. One example

is a 2/0 wire made from 5,292 strands of #36 gauge wire. The strands are organized

by first creating a bundle of 7 strands. Then 7 of these bundles are put together into

super bundles. Finally 108 super bundles are used to make the final cable. Each

21

group of wires is wound in a helix so that when the wire is flexed, the part of a

bundle that is stretched moves around the helix to a part that is compressed to allow

the wire to have less stress.

Solid wire, also called solid-core or single-strand wire consists of one piece of metal

wire. Stranded wire is composed of a bundle of wires to make a larger conductor.

Stranded wire is more flexible than solid wire of the same total cross-sectional area.

Solid wire is cheaper to manufacture than stranded wire and is used where there is

little need for flexibility in the wire. Solid wire also provides mechanical ruggedness;

and, because it has relatively less surface area which is exposed to attack by

corrosives, protection against the environment. Stranded wire is used when higher

resistance to metal fatigue is required. Such situations include connections

between circuit boards in multi-printed-circuit-board devices, where the rigidity of

solid wire would produce too much stress as a result of movement during assembly

or servicing; A.C. line cords for appliances; musical instrument cables; computer

mouse cables; welding electrode cables; control cables connecting moving machine

parts; mining machine cables; trailing machine cables; and numerous others.

At high frequencies, current travels near the surface of the wire because of the skin

effect, resulting in increased power loss in the wire. Stranded wire might seem to

reduce this effect, since the total surface area of the strands is greater than the surface

area of the equivalent solid wire, but ordinary stranded wire does not reduce the skin

effect because all the strands are short-circuited together and behave as a single

conductor. A stranded wire will have higher resistance than a solid wire of the same

diameter because the cross-section of the stranded wire is not all copper; there are

unavoidable gaps between the strands (this is the circle packing problem for circles

within a circle). A stranded wire with the same cross-section of conductor as a solid

wire is said to have the same equivalent gauge and is always a larger diameter.

However, for many high-frequency applications, proximity effect is more severe than

skin effect, and in some limited cases, simple stranded wire can reduce proximity

effect. For better performance at high frequencies, litz wire, which has the individual

strands insulated and twisted in special patterns, may be used.

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CHAPTER 6

PACKING

It is done by Packing Machine, which works automatically with controlled

overlapping. Tag printing is also done by the machine.

The packing procedure followed known as “Seaworthy packing procedure”.

6.1 Seaworthy Packing Procedure:

The seaworthy packing procedure article provides you information about packing

procedure which needs to withstand the conditions of maritime transport.

Fig. 6.1 Seaworthy Packing

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The term seaworthy packaging procedure is intended to indicate that the packaging

must additionally strengthen and withstand the conditions of maritime transport and

then resist to more severe stresses.

But you may note the most severe stresses do not occur during maritime transport

itself, but instead during cargo handling (due to impact, pushing, overturning etc.).

In below you can see a draft of seaworthy packing procedure which can be used for

industrial goods:

6.1.1 Seaworthy Packing Procedure - Vendor’s Obligations and

Responsibilities:

VENDOR shall be solely responsible for packing and marking of CARGO with

respect to handling, transport, and storage at plant site. VENDOR shall be fully liable

for proper, sufficient and adequate packing, completeness of contents, protection of

contents for a storage time of 6 months, and correct preparation of the packing list.

All damage and costs whatsoever resulting from inadequate or insufficient packing

shall be fully charged to VENDOR.

Packing and conservation of goods shall be sufficient to protect them from damage

during transit from point of manufacturer and storage at job SITE under conditions

which may involve multiple handling, extended storage, exposure to moisture and

the possibility of pilferage. The content must withstand 1 year transit conditions

without suffering damage and VENDOR shall give recommendations for further

two-year storage under SITE conditions. Required storage facilities and procedures

shall be advised by VENDOR in advance.

 6.1.2 Seaworthy Packing Procedure - Steel Structure and Plates:

Pipe, structural steel sections and plates, shall be strapped in bundles of convenient

size and weight for handling. Rolled and shaped plates shall be provided with

suitable bracing to eliminate distortion during transit, and shall be bundled in

uniform lengths. The weight of each bundle shall be within the braking strain of the

steel wrapping. Each bundle shall be marked with a metal tag, hard stamped, secured

24

under steel wrapping. A 2000 kg limitation shall be imposed for lifts in this category.

Where practicable, lengths shall be limited to 11.5 meters to avoid long carrier. All

small steel sectional handrail stanchions, gusset plates etc. shall be boxed.

Applications

Power:

Transmission Lines

Construction:

Pre-stressed concrete girders for road, river & railway bridges & flyovers.

Automobile:

Spring

Hydraulic Crane

General Engineering:

Fasteners

Cycles

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CONCLUSION

The Ramsarup Industries Ltd. is one of the largest run industries in India. It gives

employment to a large number of the people. It is a big organization working in

profit and it is really a good achievement. The working culture is quite good .The

Engineers along with supervisors and labours work as a team to complete a task. The

satisfaction of customers is top most priority of the Company.

The Ramsarup Group believes in providing best quality to their customers.

It was a good experience to work as a trainee at Ramsarup Industries Ltd.

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REFERENCES

1. Eagleson, Mary (1994), concise encyclopaedia chemistry (revised ed.),

Walter de Gruyter, p. 834, ISBN 978-3-11-011451-5.

2. Liu, David; Lipták, Béla G. (1997), Environmental engineers' handbook,

CRC Press, p. 973, ISBN 978-0-8493-9971-8.

3. Fisch, Arline M. (2003), Textile Techniques in Metal: For Jewellers, Textile

Artists & Sculptors, Lark Books, p. 32, ISBN 978-1-57990-514-9.

4. Rao, S. Ramachandra (2006), Resource recovery and recycling from

metallurgical wastes, Elsevier, pp. 179–180, ISBN 978-0-08-045131-2.

5. McCoy's RCRA Unravelled (2005 ed.), McCoy and Associates, 2005,

p. 204, ISBN 0-930469-32-1.

6. International Iron and Steel Institute; Jones, Tim (1997), Steel industry and

the environment: technical and management issues, UNEP/Earth print,

p. 76, ISBN 978-92-807-1651-1.

7. Wang, Hung & Shammas 2009, p. 1193.

8. Chisholm, Hugh, ed. (1911). "Wire". Encyclopaedia Britannica (11th ed.).

Cambridge University 2.Press Davis, Joseph R; Handbook Committee, ASM

International (2001-08-01). 

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