Infrastructure

Manufactuing of Cables
Cables with Aluminium and Copper conductor and polymer insulation are manufactured at Works at Delhi and Bhiwadi. Essentially cables comprise of conductors, insulation, innersheath, armour and outersheath.

Conductor
• Empire Cables are avialable with both aluminium and copper conductor.
• Empire Cables are manufactured with solid/ stranded circular/ shaped Aluminium/ Copper conductor.
• Stranding makes Cables flexible and easy to handle while shaping makes them compact.

Compaction is provided to all stranded conductor constructions as under:

1. Circular Conductor: With one wire in the center conductor contains 6,12,18,24,30...... wire layers in either unilay or opposite helical directions. The conductor is Compacted.
2. Shaped Conductor: In all multicore cables from 16 Sq.mm. size, conductors are "Shaped". However 6 & 10 Sq.mm. conductor can be solid/stranded circular.
3. Segmental Conductor: As a special case Empire cables of 1600 Sq.mm. are made up of segmental conductors.

Empire Copper conductor cables are of the same construction that of cables with Aluminium conductor except for high tensile strength, superior conductivity, better flexibility and ease of jointing, Copper cables are used in control, instrumentation, winding, submarine, mining and ship wiring etc. applications.

All conductors for Empire Cables are manufactured strictly in accordance with National and International specification.

National specifications - IS:8130
International specifications - IEC:60228/ BS:6360

Insulation
Insulation for Empire Cables is strictly as per National and International specifications. Empire cables are designed and manufactured with polymer dielectrics to bear thermal and thermomechanical stresses safely at continuous normal and short circuit temperature conditions.

Empire cables are available with both thermoplatic & thermo setting insulations.

PVC Cables - Thermoplastic dielectric
XLPE Cables - Thermo setting dielectric

Empire PVC Cables use PVC Compounds that take care of over load and short current with both course & fine protection systems.

Empire XLPE cables use XLPE Compound with antiu-oxidant stablizers and traces of aromatic polunuclear hydrocarbon. Thus improving electrical treeing characteristics and mechanical strength of insulation.

Pair Screening
Two core are twisted to make a Pair. A tape of Polyester is applied over the Pair and then another tape of Aluminium Mylar is applied alongwith Drain wire.

Laying Up
Cores are tested on line during production both for physical and electrical characteristics. Control is observed within tight tolerance limits for dimensions in case of PVC/XLPE insulation.

Overall Screening
A tape of Polyester is applied over the laid up pairs and then Aluminium Mylar is applied along the Drain wire.

Inner Sheath
Laid up cables are provided with innersheath of Tape/Extruded PVC with high quality of PVC which acts as bedding for steel wire/strip armouring and circularity is maintained.

In Empire cables- polymer used for innersheath are softer than insulation or outersheath & are compatible with temperature ratings of cables & do not have deleteriocus effects on any other component of cable.

The innersheath dimensions are maintained strictly in accordance with laid down specification.

Specification
For PVC Cables - IS:1554 (Part-I)
For XLPE Cables - IS: 7098 (Part-I)

Armouring
Mechanical protection to the cable is provided with armouring. Empire single core cables are armoured with Aluminium or Aluminium wire/strips, thus avoiding magnetic hysteresis losses on A.C. system.

Multicore cables are provided with galvanized steel wire/strips. Empire cables are provided with galvanized wire armouring, where cables are to run vertically and are subject to strsses.

Empire Mining Cables are armoured with double steel wire and tinned copper wires, so as to provide conductivity of armour more than 75% of main conductor of cable.

Empire cables armour wire/strips are of low resistivity material and meet the requirements of IS: 3975.

Outersheath
All Empire cables are provided with PVC/HR PVC/FR/FRLS outersheath.

Empire cables are manufactured with various characteristics of sheathing compounds.

Anti Rodent and Anti Termite Compound is applied where the customer ask for it.

PVC Compounds used for Empire cables are of various grades to meet specifications IS: 5831.

In order to be identified, Empire cables have their names embossed/printed/intended on outersheath at regular intervals.

ON the outersheath of Empire cables. Voltage grade, Cable size, Trade Name & year of manufacture are embossed, as desired by the customer.

Cables are sequentially marked for length at every metre throughout its length.

Final Testing
Each Empire Cable is tested for all applicable Routine Tests. From a lot of Cable one cable of each type is tested for Type Tests, as per relevant specifications.

Empire conduct its testing at his cable plant at Delhi for acceptance test as per specification.

Testing of Empire Cables are carried out as per Empire work standards for testing, besides applicable standards.