# 32 PROFUGO, EMERSON S.

MECHATRONICS
BS ME 5TH YR. DR. JOAQUIN
WIRES AND CABLES

1 Introduction

“Electricity” is the source of power for a nation’s economic progress, while

power cable is the major arteries for the transmission of electricity. Through

the use of various types of cables have been produced, Taiwan has

successfully promoted its industry development and economic growth as well

as the living standard of people.

For the last 4 decades, Taiwan has vigorously developed its own cable

industry. The vast majority of this product was furnished toward the

government owned power and Telephone Company.

There are many different types of power cables. Some are simple in

structure, while others are fabricated through complex process.

This particular proposal is for the plant designed to produce various kinds of

wire and cable. But we will focus on high voltage power cable (from 600V up

to 35KV), as it needs more technology and experience.

The types of cable can be produced by the machinery outlined in this

proposal are classified as follows:

1.1 Plastic Insulated Power Cable:

PVC insulated single or multi core cable made with copper or aluminum

conductors.

1.2 Control Cable:

Co-axial cable made with stranded conductors, metal tape or wire Armour.

1.3 Shipboard Cable:

Coated or uncoated solid copper, or flexible or nonflexible stranded, braided

Armour, PVC insulated.

1.4 XLPE High-voltage Cable:

Cross-linked polyethylene (PE) insulated, with or without shield or Armour,

plastic sheathed cable.

1.5 Communication cable:

The communication cable is the major diaphysis of communication

construction and information industry.

1.6 Optical Fiber:

Optic communication has low attenuation, wide band and non-induction

advantaged character.

2 General Process Description

2.1 Description of Manufacturing Process

2.1.1 Drawing

Bulk Copper is formed into wire of varying diameters by drawing it through a

series of dies.

2.1.2 Annealing

Since the drawing process causes the copper to become hard and brittle it

must be annealed.

2.1.3 Stranding

Anywhere from 20 to 100 very fine copper wires are twisted into a single

strand.

2.1.4 Twisting

Layers of wires (1+6+12+18+20 etc.) are twisted layer by layer into multiple

strands of wire. The number of layers is determined by the type of cable

being produced.

2.1.5 Braiding

Metal or non-metal mesh is braided around the cable.

2.1.6 Insulating

The copper conductors, whether they are single or multiple stranded wires,

are insulated with PE or PVC.

2.1.7 Laying

A specified number of PVC insulated copper conductors are assembled into

power cable.

2.1.8 CCV Line

Catenaries continuous Vulcanization for XLPE high voltage power cable (600

V – 35 KV).

2.1.9 Sheathing

Complete cables are formed by sheathing twin-core or multiple-core PVC

insulated copper conductors with PVC.

2.1.10 Armouring

Special purpose power cables must be incased with steel wires in order to

increase the strength of the cable.

2.2 Flow Chart of Manufacturing Process
# 32 PROFUGO, EMERSON S. IPPIS
BS ME 5TH YR. DR. JOAQUIN
GEOTHERMAL POWER PLANT

Geothermal power is energy generated by heat stored beneath the Earth's surface. Geothermal power
supplies 0.416% of the world's energy.[1] Geothermal comes from the Greek words geo, meaning earth, and
therme, meaning heat. Prince Piero Ginori Conti tested the first geothermal power plant on 4 July 1904, at
the Larderello dry steam field in Italy. [2] The largest group of geothermal power plants in the world is
located in The Geysers, a geothermal field in California.[3]

Electricity generation

Three different types of power plants - dry steam, flash, and binary - are used to generate electricity from
geothermal energy, depending on temperature, depth, and quality of the water and steam in the area.[4] In all
cases the condensed steam and remaining geothermal fluid is injected back into the ground to pick up more
heat. In some locations, the natural supply of water producing steam from the hot underground magma
deposits has been exhausted and processed waste water is injected to replenish the supply. Most geothermal
fields have more fluid recharge than heat, so re-injection can cool the resource, unless it is carefully
managed.

Flash steam

Flash steam power plants use hot water above 182°C (360°F) from geothermal reservoirs. The high
pressure underground keeps the water in liquid form, even though it is well above the boiling point for
water at sea level. As the water is pumped from the reservoir to the power plant, the drop in pressure causes
the water to convert, or "flash", into steam to power the turbine. Any water not flashed into steam is
injected back into the reservoir for reuse.[4] Flash steam plants, like dry steam plants, emit small amounts of
gases and steam.[5]

Flash steam plants are the most common type of geothermal power generation plants in operation today. An
example of an area using the flash steam operation is the CalEnergy Navy I flash geothermal power plant at
the Coso geothermal field.

Binary-cycle

The water used in binary-cycle power plants is cooler than that of flash steam plants, from 107 to 182°C
(225-360°F)[5]. The hot fluid from geothermal reservoirs is passed through a heat exchanger which transfers
heat to a separate pipe containing fluids with a much lower boiling point.[4] These fluids, usually Iso-butane
or Iso-pentane, are vaporized to power the turbine.[6]. The advantage to binary-cycle power plants is their
lower cost and increased efficiency. These plants also do not emit any excess gas and, because they use
fluids with a lower boiling point than water, are able to utilize lower temperature reservoirs, which are
much more common. Most geothermal power plants planned for construction are binary-cycle.[6]
# 32 PROFUGO, EMERSON S. MECHATRONICS
TH
BS ME 5 YR. DR. JOAQUIN
“POWER PLANT CONTROL SYSTEM”
Electricity is a vital commodity for maintaining and improving the living standards of society today. To ensure adequate and reliable
supplies of electric power whenever and wherever needed, Toshiba now offers a dynamic stream for the 21st century, the
TOSMAP-DSTM, Toshiba Microprocessor Aided Power system control - DynaStreamTM, which is a state-of-the-art Distributed
Control System (DCS) developed for total power plant control. To satisfy customer needs, TOSMAP-DSTM features:

 Comprehensive integration of plant control

 Open and flexible system
 Easy and unified engineering environment
 Fully independent Human-Machine Interface stations

 Powerful and reliable controller

Toshiba's TOSMAP-DSTM covers a wide range of

systems to meet diverse needs - geothermal power
plant control, coal fired power plant control, combined
cycle power plant control and so on. The TOSMAP-
DSTM serves as a key to provide superlative operation
and control, excellent reliability, and ease of
maintenance for power-plant control.
TOSMAP-DSTM embodies Toshiba's unrivaled
expertise in power-plant control systems, accumulated
through decades of experience supplying power
plants equipped with the latest electronic
technologies.

TOSMAP-DSTM overview

Comprehensive integration of plant controls

TOSMAP-DSTM is applicable to high-speed control, such as governor control, as well as standard control, such as heater level
control. Toshiba is not only a DCS supplier, but also a supplier of plant equipment including turbine, generator, and heat recovery
boiler. Toshiba is the power plant supplier that has decades of comprehensive experience. The integration of boiler, turbine,
generator and auxiliary control into a DCS is accomplished by Toshiba's engineering ability and the wide applicability of TOSMAP-
DSTM.
An Operator/Engineer can access/maintain all the plant control systems including boiler, turbine and generator control in the simple
manner based on Microsoft® Windows® 2000
Open and flexible system
The TOSMAP-DSTM utilizes the latest standards and de-facto standards as much as possible to make use of advanced technology
and enable an open and flexible system:

 Microsoft® Windows® 2000 for HMI and IES

 Ethernet (100M and 10M) for C-NET and I-NET
 Compact PCI bus for ACS CPU backplane
 DeviceNetTM for local I/O bus

The HMI and IES using Microsoft® Windows® 2000 provide excellent operational capability, and the C-NET and I-NET using
Ethernet, provide an open network for the entire plant communication. The expandable, compact PCI backplane of the ACS CPU
provides open system connectivity to industrial standards, and DeviceNetTM I/O bus enables a flexible interface with plant
equipment.

Easy and unified engineering environment

To achieve easy engineering, Toshiba provides an Integrated Engineering
Station (IES) that is used for engineering, system configuration and
maintenance of the HMI, ACS and C-NET. All the engineering work, TAG
database creation, logic configuration, display design and log design are unified
on the IES station. Automatic TAG linkage between the HMI data and the ACS
control logic data dramatically reduces engineering work for communication
between display information and logic inputs/outputs. The IES uses the
Microsoft® Windows® 2000 environment providing a familiar graphical user
interface using functions such as "point and click," "drag and drop", "pull down
menu" and "copy and paste".

IES
Fully independent Human-Machine Interface stations
Every HMI station provides all the functions that are essential to monitor and control a power station. This provides the maximum
level of duplication and therefore a more reliable system.
Each HMI Station in the system simultaneously and independently receives plant data via C-NET, so the failure of any HMI Station
never affects the essential data processing of other HMI Stations. Other systems that use a client/server architecture may be less
reliable, as the failure of the server may make plant operation impossible.
The supervisory software and GUI developed by Toshiba on the Microsoft® Windows® 2000 platform, provides state-of-the-art
process operation and monitoring most suitable for thermal power plants.
Powerful and reliable Controller
The ACS of the TOSMAP-DSTM system uses an advanced high-speed 32-bit microprocessor that enables the
system to meet the diverse requirements of today's power plant operation. Toshiba's supreme semiconductor
and manufacturing technology is used to realize a powerful and reliable controller. Execution time is flexibly
selectable from 50 to 500 ms according to the control requirement. An extra-high-speed controller with 1 ms
control cycle is also available for special purposes such as governor control and generator control.

Controller card
# 32 PROFUGO, EMERSON S. IPPIS
BS ME 5TH YR. DR. JOAQUIN

CABLES AND WIRE MANUFACTURING PROCESS

Electric Wires & Cables Making Plant

1. Introduction

Electric wires and cables have become such an important part of everyday

life that without them the world as we know it would simply not exist. For

without wires and cables the existence and operation of conveniences such

as electric lights, telephones, computers and a host of other household

appliances would not have been possible. Moreover, as the standard of living

rises, so does the demand for those types of products. Consequently, there

has been an incredible increase in the demand for electric wire and cable. As

developing nations around the world continue to develop, this demand will

undoubtedly continue to rise.

For example, Taiwan, the Republic of China, a country with a population

of only 19 million, has more than one hundred factories successfully

producing electric wire and cable to satisfy the needs of the domestic market.

According to an estimate made in 1984,the total production of electric wire

and cable had reached a level of 200,000 tons per year. Furthermore, the

vast majority of this cable was purchased domestically by retailers,

manufacturers, construction contractors, and the government owned power

and telephone companies. Clearly, the establishment of an electric wire and

cable making plant is a project worthy of investment.

The wire and cable making plant described in this particular proposal is

designed for the production of wire and low voltage (below 600V) power
cable. It is not intended to be used for the production of telecommunication

or high voltage power cable, as the plants capable of producing these types

of cable are considerably more expensive and require a higher level of

technical knowledge to set up. The types of wire and cable which can be

produced by the machinery outlined in this proposal are classified as follows:

I. Single wire: PVC insulated single copper conductors.

II. Multiple wires: PVC insulated copper conductors consisting of 7-61

stranded wires.

III. Flexible wire: single or twin core, PVC insulated cords consisting of 20-

100 fine copper wires.

IV. Flat twin-cord wire: twin core, PVC insulated single or multiple copper

conductors, sheathed with PVC layers.

V. Power cables: three of four cores of PVC insulated multiple copper

conductors assembled together.

VI. Armour cable: power cables consisting of three or four round and

shaped cores armored with steel wires and sheathed with PVC layers.

2. General Process Information

2.1. Process Description

(1) Drawing

Bulk copper is formed into wire of varying diameters by drawing it through a

series of dies.

(2) Annealing

Since the drawing process causes the copper to become hard and brittle, it

should be annealed.
(3) Stranding

Anywhere from 20-100 (very fine copper conductor wires) are twisted into

cords which will be used in making flexible wire and cable.

(4) Twisting

Layers of wires (1+6+12+18+24 etc.) are stranded together to make copper

conductors. The maximum nominal cross-section area of a power cable core

is 500m㎡.

(5) Insulating

The copper conductors, whether they are single wire or multiple stranded

wire, are covered by PVC for current insulation.

(6) Lay-up

Three or four of these PVC insulated copper conductors are assembled into

power cables.

(7) Sheathing

Complete cables are formed by sheathing twin-core or multiple-core PVC

insulated copper conductors with PVC.

(8) Armoring

Special purpose power cables must be surrounded with steel wires in order to

increase the cable structure strength.

*For Special Purpose Power Cable Only.

2.2. Flow Chart