Diamond Power Infrastructure Ltd.

Corporate

innovation

Profile • Innovation • Management • Chairman's Message • Vision

A philosophy of continuous improvement and the use of cutting-edge technologies have made us undisputed industry leaders in the country today.

Our state-of-the-art R&D facility provides an ideal breeding ground for pioneering innovations that are future-ready. This facility, certified by DSIR, Government of India, has been instrumental in the development of products like vacuum circuit breakers, HV switch boards, instrument transformers, CTPT sets and Bus-ducts. A professional team of engineering experts run the design, control and production processes. Conformity and reliability testing is carried out using the latest international norms.

Through continuous innovation and persistent drive, Diamond Power has ensured that world-class solutions are always on offer. We have an illustrious history of creating a product portfolio earmarked for quality and high Returns on Investment (ROI).

•	Introduced Aluminum Alloy Conductors in 1988
•	First to receive the BIS Mark for Alloy conductors in India
•	Introduced ‘Inline Solution Heat Treatment’ and ‘AC Drives on Wire Drawing Operations’
•	Introduced Aerial Bunched Cables (ABC) made from a combination of Alloy, Aluminum and Polyethylene Insulated Conductors
•	The first conductor manufacturer in Asia with an in-house Alloy Rod Mill
•	The first conductor manufacturer in the world to implement SAP ERP Systems, in 1996
•	The annual survey conducted by IEEMA in 2003, ranked Diamond Power Infrastructure Ltd. as one of the fastest growing and the most profitable cable companies in India
•	Introducing India’s first 550 KV UHV cables

HCHS Advantages
In a bid to offer products that are word class, Diamond Power has developed the HSHC conductor which is a landmark in efficacy and innovation. It offers a host of advantages that are not to be found in the AAAC and ACSR conductors that are in use today.

	Superior Tensile Strength
	An HSHC conductor has better mechanical strength than an AAAC conductor; this strength is comparable with an ACSR conductor of equal size.

	Superior Conductivity
	In comparison with an AAAC conductor, the conductivity of the HSHC conductor is higher.

	Higher Corrosion Resistance
	There are a number of unique advantages associated with the usage of a HSHC, conductor over the usage of an ACSR or AAAC conductor. There is a complete elimination of galvanized corrosion in a HSHC conductor due to absence of a steel core. This means its resistance to corrosion is better than that of an ACSR or AAA conductor.

	Another reason for a higher corrosion resistance of a HSHC conductor is the fact that the outer surface is made up of an alloy of high purity and medium strength. With respect to metallurgy these qualities lend them to higher resistance to corrosion. Higher resistance to corrosion means longer life for the overhead lines.

	On the other hand an AAAC alloy has lower purity levels as its outer core contains a wire made up of 0.5 % Silica and 0.5% Magnesium.

	Uniform Stress Distribution
	The absence of a steel core lends itself to one more advantage – uniform stress distribution. Bird caging, hence, is eliminated and the process of jointing and clamping is easier and faster

	Superior Ampacity
	Compared to an ACSR or AAAC conductor, the AC resistance of HSHC conductor is lesser; this is on account of the flow of current being at its peak in the outer periphery of the conductor in AC. If we draw comparison with an AAAC conductor, the conductivity of the outer surface is only 52.5% while the conductivity of the HSHC alloy is 59.5%.

	In comparison with an ACSR conductor, the magnetic material at the core increases the losses. This is on account of the stress and eddy current present in the steel core in center.

	Higher Stress to Weight Ratio
	The HSHC conductor is lighter than an ACSR conductor due to the absence of a steel core. This means that for the same gauge, it can have a lesser span. Also, the tower height decreases for the same span. Its superiority in this regards is also with reference to AAAC conductors as the total strength of the conductor is 6.5% more than that of AAAC conductors.

	Decrease in Creep Characteristic
	The ACSR is unconventional, hence its mechanical load and temperature causes inelastic elongation of Aluminum wires which increases the final sag of the conductor. Compared to ACSR, the creep factor is much less in the HSHC conductor.

	Decreased Gyrations
	Compared to the ACSR conductor, the gyration moment is lesser in HSHC conductors

	High Conductivity
	Area of 1+6+12 = 19 wires

	Fatigue Resistance
	Compared to ACSR conductors, HSHC conductors have a high level of resistance to fatigue. Fatigue limits have a direct relation to the subjection of a stranded conductor to repeated application of stress cycles.

	Lower Erection and Stringing Cost
	The HSHC alloy is lighter than that of the ACSR line. Also, there is an absence of steel core; together these reasons result in a longer span. Moreover, there is simplification of compression joints. Couple this will the need of singe piece compression sleeves and you have a simple, easy and cheaper installation.

	Thermal Stability
	Even at a temperature of 150 degrees, if applied for 100 hours continuously, the specially developed HSHC alloy remains thermally stable. The current carrying capacity of the overhead line, thus, increases without losing physical properties of the conductor.

	Longer Service Life
	The absence of a steel core completely eliminates bimetallic corrosion. Even corrosion as a result of the conditions of a tropical climate is eliminated due to the higher purity of the outer layer of the specially developed alloy. This increases the total life span of the HSHC conductor compared to that of an ACSR or AAAC conductor.

Continuous Cycle of Innovation

At Diamond Power, innovation is a continuous process. At any given time our R&D team is undertaking initiatives that enhance performance and improve productivity. Some of these examples are

•	Improvement of Wire Drawing Dies:
	The development focuses on the improvement of the overall design and specifically improving the lubrication and Cooling Cycle. This will help the process of high speed High Tensile Aluminum Alloy Drawing. Integrating this development in our own processes has helped us increase productivity and efficiency.

•	Heat Treatment Furnace:
	The research team undertook the redesigning of this furnace, tripling its capacity, compared to that of a conventional furnace. Another improvement was the reduction of heat loss and completely automating the loading and unloading of charges. Other improvements include fine adjustment of time and temperature cycles with auto alarm system, suitability of dual operation of solution heat treatment and ageing, amongst various others.

•	Stranding Machines:
	Product and stranding quality of cables has been achieved through the provision of an automatic loading and unloading system as well as auto wire brakes, etc.


	Copyright © Diamond Power Infrasturcture Ltd. 2011