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WIRE JOURNAL

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I N T E R N A T I O N A L

Editorial . . . . . . . . . . . . . . . . . 6

CONTENTS

Volume 45 | Number 8 | August 2012

F EATURES

Calendar . . . . . . . . . . . . . . . . 8 Industry News . . . . . . . . . . . 10 Asian Focus . . . . . . . . . . . . . 26 People . . . . . . . . . . . . . . . . . 28 Fiber Watch . . . . . . . . . . . . . 30 Fastener Update . . . . . . . . . . 32 WAI News . . . . . . . . . . . . . . 34 Chapter Corner . . . . . . . . . . . 38 Technical Papers . . . . . . . 64-77 Products. . . . . . . . . . . . . . . . 78 Classified . . . . . . . . . . . . . . . 83 Career Opportunities . . . . . . . 83

Preview: wire China 2012 . . . . . . .44 Organizers of wire China report that the numbers to date show that the 2012 staging of this biennial industry event should follow through on the positive showing in 2010.

Power Cables . . . . . . . . . . . . . . . .48 HV and EHV cables represent a very small percentage of the overall power cable market, but new and increased capacity commitments in the U.S. reflects a belief by some of the key cable manufacturers that the sector is entering a period that will see considerable volume for years to come as long-delayed grid upgrades and expansions move forward.

Advertisers’ Index . . . . . . . . . 87

T ECHNIC AL PAPERS

Next issue September 2012 • Equipment • Preview: Wire & Cable India

Zero and beyond: General Cable’s vision for safety Tim Wampler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Trends and developments in automotive wires Dr. Klaus Probst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 Commercial evaluation of TCHP dies John M. Keane and Roger N. Wright . . . . . . . . . . . . . . . .72

Cover: Driven by demand for renewable energy, the U.S. has seen considerable investment in new and expanded plants for production of HV and EHV power cable.

AUGUST 2012 | 3

INSIDE THIS ISSUE POWER CABLE MARKET SAILING ALONG . . .48

Activity was brisk at the Shanghai New International Expo Center on Sept. 21-24, 2010, when exhibitors sidestepped concerns about the gloomy global economic conditions and signed up for 74,500 sq m of exhibit space at wire China 2010 and Tube China. The events drew 26,035 attendees, and organizers are hoping for similar results this year.

HVDC power cable from ABB is deployed for a submarine cable project. News of such projects has been on the rise. Earlier this year, ABB won a $30 million order from Energinet.dk, a Danish transmission system operator, to supply a high-voltage submarine and underground power cable system for the Little Belt strait in Denmark.

CONTENTS

INDUSTRY CHINA-BOUND IN SEPTEMBER . .44

4 | WIRE JOURNAL INTERNATIONAL

EDITORIAL WIRE JOURNAL

®

EDITORIAL

I N T E R N A T I O N A L

Supply and demand only part of the equation Publisher | Steven J. Fetteroll

I try to explain to my 14-year-old son, Aaron, who believes that he absolutely needs a gaming-quality computer for his first year of high school, that just because something should be, doesn’t mean that it will be. I don’t expect him to understand, and he doesn’t. But there are some things I don’t understand myself, such as why the demand for more electric power and a “smarter” grid has not led to massive infrastructure investment in the U.S. My memory has faded, but I do recall that the days that followed the Northeast blackout of 2003 ( the worst-ever North American blackout) were full of demands for massive improvements to the power grid.

The Aug. 14 blackout shut down power parts of the Northeastern and Midwestern United States and Ontario, Canada. Some10 million people in Ontario and 45 million in eight U.S. states were in the dark. The blackout cost an estimated $6 billion and was tied to at least 11 deaths.

So why did nothing of consequence happen in the months and years that followed? To a degree, the problem was quite complex. The electric grid is not a single entity, making it very difficult to establish a concensus as what should be done and how it would work. There was the ever-present financial aspect, as in terms of who (energy generator or distributor) would pay. It was more than a matter of simply adding more power generation sites as a “smart grid” was needed to better direct and control movement of power unto itself. And pressure for more renewable energy further mucked up the waters as most prime locations for wind and solar were far from core energy demand.

“It is a real issue, a chicken-and-egg problem,” said John Kassakian, an MIT professor of electrical engineering who co-chaired a study cited in the feature that begins on p. 48. “Nobody’s going to build these new renewable energy plants unless they know there will be transmission lines to get the power to load centers. And nobody’s going to build transmission lines unless the difficulty of siting lines across multiple jurisdictions is eased.”

Nine years later, there is more general consensus and the technology has made progress seem feasible. Some issues have yet to be resolved, but when companies like ABB, Nexans, Prysmian and LS Cable & System are willing to invest big-time in EHV cable in the U.S., you’ve got to believe that the outlook is getting better.

Mark Marselli Editor-in-chief

Editor-in-Chief | Mark Marselli Senior Graphic Designer | Bill Branch Director of Sales | Robert Xeller Advertising Sales | Anna Bzowski Director of Marketing & Corporate Communications | Janice E. Swindells Graphic Artist | Adrienne E. Simpson Proofreader | Livia Jacobs Publications Advisory Board Ferruccio Bellina | TKT Group/President ACIMAF, Italy Malcolm Michael | AWIA Australia Don Schollin | Q-S Technologies, USA Ralph Skalleberg | Skaltek USA Dave Stackpole | Nutmeg Wire, USA Giulio Properzi | Continuus Properzi, Italy Robert Wild | Niehoff Endex North America, USA Technical Advisors John Drummond | Scotia Group R. M. Shemenski | RMS Consulting, Inc.

WIRE JOURNAL INTERNATIONAL (ISSN-0277-4275) published monthly by The Wire Journal, Inc., is a wholly owned subsidiary of The Wire Association International, Inc., which is located at 1570 Boston Post Road, P.O. Box 578, Guilford, CT 06437-0578, USA, and can be contacted at tel.

203-453-2777; fax 203-453-8384; Internet wirenet.org; e-mail mmarselli@wirenet.org. Address all correspondence concerning advertising production, editorial and circulation to the above address. WJI is printed in USA. Subscription rates: $110 per year, USA; $120 per year, Canada and Mexico; other countries, $140 per year (includes air mail). Back copies: $10 WAI members, $15 non-members. Periodicals postage paid at Guilford, CT 06437, USA, and at additional offices.

Wire Journal International grants photocopy permission to libraries and others registered with Copyright Clearance Center (CCC), 21 Congress St., Salem, MA 01970, USA, for a fee of $0.50 per article. Payments should be sent directly to the CCC. Requests for bulk orders or reprints should be sent to the Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA. © 2012 by Wire Journal, Inc. All rights reserved. The Publisher of WJI assumes no responsibility for the validity of manufacturers’ claims made herein. Back issues of WJI are on microfilm and available from University Microfilm, 300 North Zeeb Road, Ann Arbor, MI 48106, USA. Phone: 313761-4700.

POSTMASTER: Send address changes to Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA.

6 | WIRE JOURNAL INTERNATIONAL

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CALENDAR

CALENDAR Sept. 25-28, 2012: wire China 2012 Shanghai, China. To be held at the Shanghai New International Expo Centre (SNIEC). Contact: Messe Düsseldorf North America, tel. 312-781-5180, fax 312-781-5188, info@mdna.com, www.mdna.com.

Oct. 3-5, 2012: SpringWorld 2012 Rosemont, Illinois, USA. To be held at the Donald E. Stephens Convention Center. Contact: Tom Renk, The Chicago Association of Spring Manufacturers, Inc. (CASMI), tel. 630-369-3466, fax 630-369-3773, info@casmi-springworld.org, www.casmi-springworld.org.

Oct. 29, 2012: International Technical Conference (ITC) Mumbai, India. This multi-industry association event, to be led by U.K.-based International Wire & Machinery Association (IWMA) and supported by WAI, will be held in conjunction with the Oct. 30-Nov. 1 staging of Wire & Cable India in Mumbai, India. It will include technical papers, networking opportunities and more. Contact: WAI, sfetteroll@wirenet.org, IWMA, www.iwma.org.

Oct. 30-Nov. 1, 2012: Wire & Cable India Mumbai, India. This event is organized by Messe Düsseldorf. Contact: Messe Düsseldorf North America, tel. 312-781-5180, fax 312-781-5188, info@mdna.com, www.mdna.com.

Nov. 11-14, 2012: 61st IWCS Conference™ Providence, Rhode Island, USA. To be held at the Rhode Island Convention Center. Contact: Pat Hudak, IWCS, www.iwcs.org, phudak@iwcs.org, tel. 732-389-0990.

Nov. 15-18, 2012: Cable & Wire Fair Istanbul, Turkey. To be held at the CNR Expo Center, this event, organized by CNR Holding, includes cable accessories, cable realignment, electrical insulation materials, equipment and machines. Contact: Esra Aydin,

CNR Holding, tel. 90-0212-465-74-74/2-22, esra.aydin@cnr.net, www.cnrexpo.com or www.cnrcablewire.com.

Nov. 15-18, 2012: Wire & Cable Asia 2012 Shanghai, China. This new event is being organized by U.k.-based Integer Research, www.integer-research.com.

April 23-25, 2013: Interwire 2013 Atlanta, Georgia, USA. WAI returns to the Georgia World Congress Center to stage its trade show, technical programs and the Association’s 83rd Annual Convention.

May 2013: wire Russia 2013 Moscow, Russia. Contact: Messe Düsseldorf North America, tel. 312-781-5180, fax 312-781-5188, info@mdna.com, www.mdna.com.

Sept. 17-19, 2013: wire Southeast Asia Bangkok, Thailand. Contact: Messe Düsseldorf North America, tel. 312-781-5180, fax 312-781-5188, info@mdna.com, www.mdna.com.

Oct. 8-13, 2013: wire South America 2013 São Paulo, Brazil. Messe Düsseldorf and its partner Grupo Cipa will stage this new fair for the Brazilian market. The new event will be held in parallel with TUBOTECH at the Imigrantes Exposicoes Exhibition Centre in São Paulo. Contact: Messe Düsseldorf North America, tel. 312-781-5180, fax 312-781-5188, info@mdna.com, www.mdna.com.

April 7-11, 2014: wire Düsseldorf Düsseldorf, Germany. This biennial event will be held at the Messe fairgrounds. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.

WIRE A SSOCIATION INTERNATIONAL EVENTS For more information, contact the WAI, USA. Tel. 001-203-453-2777; fax 001-203-453-8384; www.wirenet.org.

Sept. 10, 2012: New England Chapter 18th annual golf tournament Ellington, Connecticut, USA. This event will be held at the Ellington Ridge Country Club.

Oct. 22, 2012: Western Chapter 12th annual “Wild West Shootout” golf outing Rancho Palos Verdes, California, USA. This event will be held at the Los Verdes Golf Course.

Oct. 18, 2012: The Vannais Southeast Chapter 11th annual golf tournament Conover, North Carolina, USA. This event will be held at the Rock Barn Golf & Spa.

April 23-25, 2013: Interwire 2013 Atlanta, Georgia, USA. WAI returns to the Georgia World Congress Center to stage its trade show, technical programs and its 83rd Annual Convention.

8 | WIRE JOURNAL INTERNATIONAL

INDUSTRY NEWS

INDUSTRY NEWS Prymsian Group supplies 350 km of cables for record U.K. skyscraper The Prysmian Group reports that it has supplied some 350 km of high-tech power cable for the Shard, an 87story tall skyscraper that is the tallest building in Western Europe.

A press release said that the company supplied high-tech fireresistant cables for power distribution within the Shard skyscraper, a distinctive building described as a “cone of light 310 meters and 87 floors tall completely covered with glass panels.”

Construction of the building, designed by architect Renzo Piano in 2000, began in 2009, and in 2011 the The Prysmian Group was a supplier Prysmian Group for the Shard, a U.K. skyscraper. won the contract to supply its Afumex™ low-smoke zero-halogen cables, FP600S cables and medium-voltage power cables.

The Group’s British subsidiary was chosen as global supplier of BASEC and LPCB certified cables and components, and of support and advice to the construction company on the best installation methods to use, it said.

ESAB Welding and Cutting Products opens new plant in South Carolina U.S.-based ESAB Welding and Cutting Products has opened a new welding wire plant in Union County, South Carolina.

A press release said that the 260,000-sq-ft plant is a stateof-the-art production site that saw an extensive refit of the structure—originally built in the 1970s—for the manufacture of welding wire. The plant, which will have approximately a hundred employees, will house the production of ESAB’s high-performance MIG and submerged arc welding wire as well as two new production lines of the company’s premium brand AristoRod and copper-coated wire, it said.

“We believe that we will continue to see steady growth in

the North American market, and this move to Union County represents an increase in production capacity and the transfer of lines that were being manufactured overseas,” said Sue Bartholomew, ESAB global marketing director. The release said that ESAB invested millions of dollars for the plant update, with improvements including new power distribution, piping, lab equipment, material handling equipment, a complete fume collection system and more.

GCR Eurodraw commissions saw wire plant in China’s Sichuan Province GCR Eurodraw reports that it has successfully commissioned a saw wire plant for Sichuan Ruiyu Photovoltaic Materials Co., Ltd., a company of the ReneSola Group that is based in the Sichuan Province of China.

A press release said that GCR Eurodraw supplied the complete plant, which is designed to produce 9,000 metric tons a year of saw wire a year, starting from steel wire rod.

It noted that ReneSola is a global manufacturer of solar wafers and provider of solar module OEM services. The release said that ReneSola has developed new G6 mul-

A GCR engineer with employees by the brassing line of the new ReneSola saw wire plant. ticrystalline furnaces based on G5 ones, that further improve the production capacity of the silicon wafers.

“ReneSola has been in a leading position of the solar energy industry and provided customers worldwide with high-quality solar products to make the solar energy industry better,” it said.

Southwire to supply 500 miles of HCDV cable for CleanLine project Southwire Company has been chosen to supply 500 miles of overhead, high-voltage direct current (HVDC) transmission lines for the Rock Island CleanLine project, which will deliver 3,500 megawatts (MW) of renewable power from four states to communities and businesses in Illinois and other states to the east. See p. 52.

Does your company have news that belongs here? E-mail it to the WJI at editorial@wirenet.org.

10 | WIRE JOURNAL INTERNATIONAL

Millions of people saw Nik Wallenda cross Niagara Falls on June 15, and among those who watched the spectacle televised by ABC were employees of U.S.-based Wirerope Works, Inc., which provided the 2,500-ft-long wire rope that was used for the crossing between Niagara Falls, New York, and Niagara Falls, Ontario.

“It was exciting for all of us,” said Project Engineer Kim Konyar, who was the Wirerope Works staffer who worked with Nik Wallenda’s team. The company, which manufactures Bethlehem Wire Rope, had previously made a wire rope for Wallenda several years earlier but that one has not been used yet, although it may be used for a planned crossing of the Grand Canyon, he said.

The two-in. wide, 6 x 49 wire rope itself was not that unusual, Konyar explained, noting that it is basically what would be provided for large cranes or slings.

The one unusual request, an understandable one, was that Nik had asked that there be no grease inside the finished wire rope, he said. “We told him that that could result in the wire rope rusting by the time it was to be used, but he said that would actually Nik Wallenda toes the line on a be a plus,” he Wirerope Works wire rope as he recalled, noting the crosses Niagara Falls. Wikipedia following, which photo. also includes details from reports by Michael Woods and Liam Casey in The Star and one in Wikipedia.

In lieu of a traditional lubricant, a water-based die compound was used. Die heat was not a problem as the planetary system that twists the strands ran at relatively slow speeds. The rope weighed about seven tons, a little over seven pounds a foot length. It was tensioned to one-fifth of the breaking point (a five-to-one safety factor) for a maximum sag of 70 feet. The 1,800-ft-long wire was pulled across the gorge, with weighted pendulums placed every 45 meters, alternating between three meter and six-meter long pendulums. Each pendulum had a 23- to 36-kg weight on the bottom to prevent the wire from twisting.

INDUSTRY NEWS

Wallenda’s ‘walking the walk’ across Niagara Falls was done on a Wirerope

Project Engineer Kim Konyar displays a portion of the wire rope type that Wirerope Works, Inc., supplied to Nik Wallenda for his Niagara Falls crossing.

O’Connell Electric of Victor, New York, the riggers for the project, set the wire rope in place. A helicopter flew a yellow rope across the canyon. The rope was attached to the steel high-wire and a giant winch was used to pull the wire across as the crew slowly increased tension to support the increasing weight.

Wallenda, who was required to wear a tether for the crossing, crossed the Falls in a little less than a half hour, the spectacle at times turning surreal as he was dwarfed by the pounding waters below. Not long after he crossed to the cheers of the crowd, he turned over his passport as his feat had required him to cross the U.S.-Canadian border. By 6 am the next day, the wire rope had been removed by the rigging crew. The wire rope essentially was a one-time use, and one source said that it may be cut up and sold as commemorative pieces.

“Wirerope Works, Inc., and all of its employees are thrilled to be part of this story,” said Virgil Probasco, executive vice president. “We hope that Bethlehem Wire Rope will be the rope of choice for future walks by Mr. Nik Wallenda.”

Leoni AG joins Desertec consortium Germany’s Leoni AG reports that it has become an associate partner in the Desertec Consortium, an ambitious group effort that seeks to create a market for desert power to supply North Africa, the Middle East and Europe (EUMENA region) with clean energy.

A press release said that Leoni will help the industrial initiative—known as Dii—and its international business network, realize the Desertec vision by contributing products and services to help raise the efficiency of solar thermal and photovoltaic power plants. The long-term strategic goal for Dii, spelled out in “Desert Power 2050: Perspectives on a Sustainable Power System for EUMENA,” demonstrates “that a power system based on more than 90% of renewable energy is technically possible and AUGUST 2012 | 11

INDUSTRY NEWS Leoni AG’s technology will be added to the Desertec Consortium’s capabilities. economically viable,” it said.

“Leoni has more than three decades of experience with its facilities in North Africa and currently employs about 25,000 people in the region. It is not least for this reason that we are certain that we can make a rewarding contribution to the Desertec project,” said Dr. Klaus Probst, Chairman and CEO of Leoni AG. “We are pleased that Leoni as the biggest employer in

Tunisia is a new associated partner of our initiative,” said Dii Managing Director Paul von Son. “(We) can make a valuable contribution to reducing the power plants’ construction cost.” The objective, he said, is to set up a sustainable, reliable and affordable electricity supply system based on renewable energy for the EUMENA region.

The release said that Leoni has recently begun to supply solar thermal plants, mostly with assembled cable systems.

“Their big advantage is that they are plug-and-play capable.

Because they are industrially pre-assembled, they can be rapidly installed without involving any experts. That pays off. Firstly, it only takes up half as much time to trim, cut and fit the cables with connectors in the factory than in the usually uncomfortable surroundings of a solar power plant field. Secondly, labor costs are lower in a factory than in field installation. Overall, assembly and installation costs are reduced by about 75%.”

AMSC reports HTS wire contract U.S.-based AMSC announced that it has been chosen as the high temperature superconductor (HTS) wire provider for a European maritime project called POSE2IDON. A press release said that POSE2IDON (Power Optimised Ship for Environment with Electric Innovation Designs Onboard) is a 20-million euro project funded by the

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INDUSTRY NEWS

European Union. The goal, it said, is to provide “a working guide on how to improve the efficiency and reduce the environmental impact of Europe’s commercial shipping fleet through the use of HTS rotating machines and distribution networks.” Large-scale motor and generator demonstrators using AMSC’s HTS wire are expected to be made and tested by the end of 2013, it said.

“We see great promise for superconductors in the maritime industry,” said POSE(2)IDON Coordinator Chris Hodge. “The technologies developed in this project will enhance cargo space availability and efficiency on electric ships while at the same time reducing carbon emissions.”

The release said that AMSC has designed, built and tested HTS rotating machines, including a 49,000 hp HTS ship propulsion motor. “AMSC continues to work with organizations, corporations and nations ... to overcome long-standing energy challenges through super-conductor-enabled solutions,” AMSC President and CEO Daniel. P. McGahn said. “In the maritime industry, superconductors can be applied to a range of systems, such as motors, generators, power cables and protection systems, freeing up precious cargo space, enhancing ship defense and reducing energy consumption, fuel costs and greenhouse gas emissions. We applaud the European Union for recognizing the transformative impact that HTS can have ...”

14 | WIRE JOURNAL INTERNATIONAL

LS Cable reports winning its first contract from French utility EDF South Korea’s LS Cable & System reports that it has become the first Korean company to win a contract from EDF (Électricité de France), Europe’s largest power generation company.

A press release said that the contract calls for LS Cable to supply 5.5 km of 225kV extra-high-voltage cables and attendant connectors for the La Rance Power Station that is located in Bretagne in northwestern France. As part of the contract, it said, the company will also be responsible for supervising the laying of the cables and installation of the connectors.

The release said that EDF is the world’s second largest electricity producer, providing many countries with consulting services on installation and operation of electric power grids. The business is known for its strict quality control and thorough construction management, therefore, winning the order was a major achievement, it said.

“Since we started overseas market entry, we have always been looking forward to supplying our products to France, a center of advanced power technologies,” said LS Cable & System President & CEO Jongho Son. “With this success we will further accelerate our global market entry.”

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Prymsian Group supplies the power cables for China ferry terminal The Prysmian Group reports that it has won a contract worth 5 million euros to supply high-tech power cables for the new Macau Taipa Ferry Terminal in Macau, China.

A press release said that the terminal is part of a strategically important infrastructure linking the sea transportation in the Guangdong area (South China) covering Macau, Hong Kong and Zhuhai. The contract, it said, calls for Prysmian to design, supply, install and commission special fire-resistant cables, in cooperation with BBC Cable Engineering, a local partner in the area. The high-tech power cables, it said, feature electrical and mechanical char-

acteristics able to increase the level of safety in case of fire and stay functional even if directly exposed to fire, ensuring the supply of energy and the operation of signaling systems.

The company, it said, has developed a complete range of high-performance cables for the construction and infrastructure sector (FP200 Gold, FP Plus, FP100, FP400, FP & FP600S Firefix). Installation is scheduled for completion by the end of 2013.

The contract has strategic value, due to its being awarded in China, the release said, noting that in the country the Prysmian Group employs more than 1,500 employees in nine manufacturing plants, including Baoying (high-voltage cables), Tianjin and Suzhou (special cables for industrial applications), Suzhou (systems and network components), Shanghai (submarine cables), Wuxi (optical cables), Wuhan (optical fibres and multimedia systems), Nantong Haixun and Nantong Zhongyao (elevator systems).

The Chinese market, the release said, represents approximately 20% of the entire cable industry worldwide. It noted that the Prysmian Group recently completed an investment worth 20 million euros to expand its plant in Baoying, doubling the production capacity and promoting the introduction of new technologies, such as the new vertical continuous vulcanization (VCV) tower, able to produce high-voltage and extra-high-voltage cables 2,500 sq mm up to 500 kV.

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The release said that LS Cable & System “has once again verified that its technological power and product competitiveness are of the world’s highest standard as it was selected for this EDF project amidst fierce competition against European cable makers who enjoy significant influence in global markets.” In particular, having succeeded in winning the contract through close cooperation with its U.S. subsidiary, Superior Essex (SPSX), LS Cable & System has demonstrated that its global cooperation system is being effectively implemented, it said.

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Egypt’s El Sewedy Electric reports that it has signed a US$26 million contract with the Société Nigérienne des Télécommunications (SONITEL) to supply the Niger national telecom carrier with a fiber optic cable system to create a new backbone link between three areas in Niger.

“We are extremely optimistic on the potential for Elsewedy Electric to assist Niger in developing its communication and power needs,” said El Sewedy Electric CEO Ahmed El Sewedy. He noted in a press release that the electrification rate in Niger stands at 4% with only 145 MW of installed capacity. “Niger is committed to have an installed capacity of about 350 megawatts of electricity over the coming years and we believe this presents a great opportunity for Elsewedy Electric in that we will be able to support the Niger government to achieve its target and realize this growth,” he said.

The project completion date for the fiber optic cables system is expected to be within 12-15 months from the signing of the contract.

Industry report: ‘cloudy’ days appear to be ahead for enterprise networks

over 100 million Apple iPhones and over 20 million Apple iPads, the release said. Mobile device shipments, it noted, are now exceeding PC shipments, and as a result, “this technology is already impacting the SCS market.”

Large enterprises have been investing more than $100 billion in cloud computing services the last three years, the release said. Most enterprises, it said, are currently evaluating the role of cloud computing in their future networks.

“Until now, most of this is being trialed to gain experience for future deployment. Cloud computing services are expected to start being widely deployed next year. As a result, this technology is expected to impact the SCS market starting next year. These two technologies are changing the enterprises’ network architecture resulting in a major change for the structured cabling system required to support the new network architecture,” it said.

“Our analysis indicates that copper cabling and fiber cabling will be affected differently, with the net result being the reduction in the SCS market size and growth,” the release said. By 2017, the two technologies will reduce the SCS market from $9.9 billion to $9.1 billion. Growth over the five-year period, it projected, will decrease to 3.3%.”

For more details, contact FTM Consulting at tel.

717-533-4990, contact@ftmconsultinginc.com, www. ftmconsultinginc.com.

A new report from U.S.-based FTM Consulting, “The Post-PC-Cloud Computing Era SCS Market Report,” notes that the enterprise networks sector is entering a new technology era that will result in major changes.

“This change will impact the SCS (structured cabling systems) market in a negative way. We call this, ‘the Post-PCCloud Computing Era,’” said Frank Murawski, president of FTM Consulting, Inc. “Post-PC implies that PCs are no longer the network’s primary access device. Rather, smartphones and tablets are increasingly being used to access the enterprise’s network.”

A press release outlined some of the changes that are impacting the field, including “one popular buzzword, BYOD (bring your own device)...(which) allows employees to bring their own mobile devices to access the enterprise’s network.” The other technology, it said, is cloud computing, whereby computing resources are provided, as a service, rather than a product, by third party service providers.

Cloud computing has developed a compelling business case for financial and deployment timing as it is provided on a usage basis, such as a utility’s metered service, it said. That can happen without a large IT department capital investment, and cloud computing services can be provided in a matter of weeks, if not days, whereas the IT department would initiate a multi-month or even a multi-year project to provide new network services, it said. Beyond that, cloud computing services have gotten a lot of attention by the technological giants such as IBM, Intel, Microsoft, Amazon and Google.

Mobile devices have seen recent stunning growth, with 3.6 billion devices shipped by the end of 2010, including

AUGUST 2012 | 17

INDUSTRY NEWS

El Sewedy Electric winning contract from Niger telecom carrier SONITEL

INDUSTRY NEWS

group is asking the Nuclear Regulatory Commission to require all plants to better monitor such cables and wires Miles of vital electrical cables and wires at most of and to demonstrate that they will function as required.

America’s 104 nuclear power plants are at risk of failure “A failure of such a cable or wire could ... produce catadue to prolonged submersion in water or condensation, strophic consequences during an accident,” said NRDC warns the Natural Resources Defense Council (NRDC).

Nuclear Program Scientist Jordan Weaver. The NRDC petiA press release said that the environmental advocacy tion said that some of the aging cables are protected by insulation with theoretical lifetimes of nearly 10,000 years, but that is in a dry environment, and if they were submerged in water or exposed to high humidity, the lifetime could be just hundreds of hours.

“This is an unacceptable Faustian bargain, placing the public at risk to Features: avoid a major expense to nuclear plant • Improved bow strength operators and could result in a total (no holes) loss of electrical power similar to the • Wire is out of the air cause of the Fukushima meltdowns,” stream said Paul Blanch, who is a consultant • Bow shaped like a wing for with more than 45 years of experience improved aerodynamics in nuclear and electrical engineering. and low cw factor “One critical need is to develop better • Wear strip eliminated and testing methods and qualification proreplaced by wear bushings grams that can detect defects in such with windows for easy cables and wires, so that replacements inspection and dust or upgrades can be made. Existing cleaning methods and regulations lack the abili• Wear bushings can be ty to demonstrate that these cables will changed while bow is perform properly during an accident,” mounted on the rotor he said.

Asked by WJI if this was a theoretiAdvantages: cal problem or if there had been cables • Lower power (amps) found that posed a safety concern, consumption and reduced Weaver responded, “We are not claimnoise ing that cables are not tested in wet • Higher TPM - maintaining environments, but that plants are not wire quality monitoring the degradation of dry• Reduced elongation @ environment rated cables installed in higher TPM areas that are commonly exposed to • Reduced bow breakage moisture. When we say ‘industry’ in • Increased life on wear our petition, we are generally referring surfaces reducing downto the nuclear power industry and not times and maintenance the cabling industry.”

• Wire breaks are contained within the bow - extending CCCA names officers, bow life

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The Communications Cable and Connectivity Association (CCCA), a U.S.-based non-profit corporation serving the networking, IT and communications industries, recently named its new officers at its annual meeting.

Elected to officer positions are: Bill Kloss, OFS, CCCA chairman of the board; Randy Mortensen, Anixter,

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secretary; and Scott Brown, General Cable, treasurer.

Joining the officers on CCCA’s Executive Committee are Kevin Ressler, TE Connectivity, and George Pruce, DuPont.

news in brief Encore Wire Corporation President and CEO Daniel L. Jones has been named a regional winner in the Ernst & Young Entrepreneur Of The YearÂŽ 2012 Award in the Distribution and Manufacturing category. Jones, who has served as president and CEO since February 2006, joined the McKinney, Texas, company as director of sales in 1989.

He served in key positions during a period that saw the Fortune 500 cable company, founded as a start-up in 1989, grow to the second largest U.S. Daniel L. Jones rang the New York Stock producer of Exchange’s opening bell on July 18 building cable.

Encore Wire’s annual sales have topped US$1.2 billion, and under his leadership, the Fortune 500 company has continued to increase its market share and undergone ambitious expansion, including the building of a $30 million armored cable plant in 2006, a $5 million tray cable plant in 2008, a $6 million R&D Center in 2010 and, most recently, a $30 million aluminum wire plant scheduled to be running by the fourth quarter of this year. Despite the downturn that started in late 2008, the company has added hundreds of employees. A dedicated fitness enthusiast, Jones—who also rang the opening bell for the New York Stock Exchange on July 18—is known for his determination and empowering his staff, telling them when in doubt, to “Just do the right thing.� The company recently was named one of the “100 Most Trustworthy Companies in America� by Forbes Magazine, and won the “Texas Manufacturing Star Award� from the Texas Workforce Commission. Company Vice President and CFO Frank J. Bilban won the Dallas Business Journal CFO of the Year Award in the Small Public Company category. ... The Thermoplastic Elastomer Division of Teknor Apex Company has named three polymer distributors in Europe to represent its entire range of TPE compounds. The appointments follow the company’s integration of the SarlinkŽ range of thermoplastic vulcanizate (TPV) elastomers (acquired from Royal DSM N.V. in 2010) into its portfolio of other TPE prod-

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ucts.“Teknor Apex is now the most diversified manufacturer of TPEs, offering product families based on six generically distinct polyolefin, styrenic, and vulcanizate chemistries,” said Barry Galpin, European sales director. “Customers

22 | WIRE JOURNAL INTERNATIONAL

in Ireland, Italy, and Scandinavia now can go to one source for all of these materials, making it easier for them to select precisely the right compound for their application.” Italy’s Chemieuro Italia SrL becomes the company’s first distributor to represent Teknor Apex’s TPE brands throughout the country. It can be contacted at tel. 39-2-8-90-46-61, milano@chemieuro.com, www.chemieuro.com. Sweden’s Erteco Rubber & Plastics now also represents Sarlink products in Denmark, Finland, Norway and Sweden. It can be contacted at: tel: 46-08-587-517-00, order@erp.se., www.erp.se. Ireland’s J.L. Goor Material Ltd. has also added Sarlink products to its range of Teknor Apex TPE brands. It can be contacted at tel. 353-1-829-3252, materials@jlgoormaterials.ie, www.jlgoormaterials.ie. ... Ducab, a UAE manufacturer of wire and cable, was one of 54 companies that were chosen from a list of 1,341 companies to achieve “Superbrand” distinction. Jointly owned by the Investment Corporation of Dubai and the General Holding Corporation (GHC), Ducab operates five manufacturing facilities in the UAE and has supplied wire and cable for multiple landmark projects.

The company, which reports that its manufacturing capacity tops 105,000 copper metric tons of high-, medium- and low-voltage cable, notes that its 2011 revenues rose 39% from the prior year. “We are absolutely delighted to receive this recognition for the fourth time,” said Ducab Marketing Manager Ashish Chaturvedy. “Every week Ducab produces ten million meters of insulated building wire cables, which is enough each month to circle the globe. After our tremendous success in local and regional markets, the Ducab brand is now gearing up to explore market opportunities in Europe, Asia and Africa.” ... Earlier this year, the nonferrous division of Italy’s MFL Group (FRIGECO) organized technical conferences in Mexico to explain the latest technologies and products that the company is able to offer the wire industry. At two locations in Mexico (Mexico City and Monterrey), topics that were discussed included technical matters related to the company’s

INDUSTRY NEWS

Attendees at a FRIGECO technical conference in Mexico. full range of drawing machines, stranding machines and cable insulating lines, focusing on the advantages and innovative solutions that are offered. The sessions drew some 65 technicians from more than 10 different Mexican companies. Due to the success of the event, the MFL Group said that it plans to repeat the experience in other countries of the region, the goal being to make customers in Central and South America more fully aware and confident about FRIGECO’s capabilities as a supplier. ...

U.S.-based Northwire, Inc. (NWI), recently introduced “Lab 360,” a contract manufacturing platform that is a customer-focused engineering model that includes six collaborative phases. From concept to completion, Northwire engineers engage with customers through every process phase to ensure their exact requirements are met, a press release said. Customers engage Lab 360 early in the process at the idea or concept stage and NWI’s Lab 360 experts translate customer requirements through R&D, new product development, prototype, pilot models, clinical trials, low volume through high volume production, life-cycle innovation and logistics, it said, noting that custom products are delivered in five days or fewer, quotes in 24 hours or less, and that rapid solutions for connectors, assemblies, and contract manufacturing are available upon request. The company noted that, earlier this year, its New Mexico and Wisconsin manufacturing facilities were certified to ISO 13485:2003,

24 | WIRE JOURNAL INTERNATIONAL

which covers the design and manufacture of wire, cable and assemblies for medical devices and related services. ...

WireCo WorldGroup Inc. (WireCo), a U.S.-based manufacturer of wire rope, electromechanical cable and wire products, reports that it has acquired Koninklijke (Royal) Lankhorst Euronete Group B.V., a manufacturer of synthetic ropes, industrial yarns, netting, yachting products and recycled plastic products based in the Netherlands. “In particular, its market position supporting the maritime, fishing and offshore markets provides a strategic fit with existing WireCo product lines,” a press release said. “We invested in this acquisition for two key reasons: it places WireCo as a market leader in synthetic ropes, matching our position in value-added steel wire ropes, and it provides WireCo with the most advanced products and technical expertise globally in synthetics,” said WireCo CEO Ira Glazer. “With this acquisition we continue to diversify our business mix by product, geography and end market.” Other recent WireCo acquisitions include Phillystran in 2009, Oliveira in 2010 and Drumet in 2011.

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ASIAN FOCUS

ASIAN FOCUS India’s Jindal Steel & Power finds Bolivia a tough place to expand Making a major investment on another continent is an ambitious direction for any manufacturer, and it is understood that the lure of an expanded global presence and new long-term revenue streams comes with risk. As spelled out in numerous media accounts, that latter reality was experienced by Jindal Steel & Power Ltd. (JSPL), an Indian steel company that had great hopes and planned investment in Bolivia, only to see a multi billion-dollar deal fall apart, with both sides blaming each other.

At its website, JSPL—which is active in steel, mining and power generation—notes that, having established a strong base in the domestic market, it was reaching out to South America to expand its global presence, exploring business avenues in high growth markets. The Bolivian venture had been a long time in the making, as in 2007 JSPL had acquired development rights for 20 billion metric tons of the country’s EL Mutun iron ore reserves. Plans called for the company to invest US$2.1 billion over a period of years to mine and set up an integrated 1.7 million metric ton (mmt) steel plant, 6 mmt sponge iron capacity and a 10 mmt iron ore pellet plant. This, it said, would be “the largest and the first of its kind investment by any Indian company in Bolivia and also the largest foreign investment in a single project in Bolivia.”

Only that dream officially ended recently, when JSPL— which entered a 40-year joint venture agreement through its subsidiary, Jindal Steel Bolivia S.A (JSB), and Empresa Siderurgica Del Mutun (ESM), a Bolivian government entity—pulled out, claiming that the government had not met its obligations. The government, meanwhile, claims that JSPL had failed to meet its investment obligations.

The company said that it took the decision, after all its efforts to resolve issues and “take the project forward” did not succeed. The Bolivian government was to have signed an agreement to supply JSB with 10 million cubic meters (mcm) of natural gas per day for the operation to run within a half-year of the contract signing. That has not happened, the statement said, noting that the government would only commit to providing 2.5 mcm of gas. It also said that representatives for the Bolivian government did not provide the agreed contract area for setting up the steel project.

JSB sent a June 8 letter to the Bolivian government noting its intent to terminate its contract and it followed up on July 17 with a letter noting that it had, indeed, pulled out. “Due to the non-fulfillment of the contractual obligations and unwillingness to fulfill the contract on the part of the government of Bolivia, JSPL has been forced to terminate the contract,” it said. “In view of the aforesaid breaches of the Bolivian government and its entities, the company intends

to pursue international arbitration relating to the contract.”

For emphasis, the letter also included a subhead that read, “The termination comes due to the anti-investor friendly attitude of the Bolivian Government.” Employees are to be laid off in September.

JSPL, whose product lines include wire rod, appeared to have gotten off to a slow start after it signed the agreement with the administration of Bolivian President Evo Morales.

It was not till 2010 that JSB secured the land to start the

India’s Jindal Steel & Power Ltd., has grown its steel, mining and energy transmission businesses, but it encountered unexpected challenges in Bolivia. project, and it blamed the delay on lack of support from the Bolivian government. The company started exporting iron ore in early 2011. In its June “intent” letter, JSB noted that it had invested more than US$90 million to date for the project and had made commitments topping US$600 million to March 2012.

Reports in India’s Economic Times and other publications said that JSB had long had a volatile relationship with the Bolivian government. Further strain came when the company stopped shipping iron ore because the water levels in the Tamango canal had fallen with the onset of winter, and the ore had to be shipped on barges.

Morales is reported to have threatened to send in the Navy to ship the ore if JSB would not do it. He also denied that the company had not gotten its gas commitments and furthermore said that, because of the circumstances, the government had the right to seize the company’s US$18 million performance bond.

Jindal executives have said that leaving Bolivia would not pose a major loss to the company, although it would affect its plans to establish a strategic presence in South America.

Mines Minister Jose Pimentel has said that a revision or reversal of the agreement can happen only after a government audit of JSB’s investments in May next year.

Have news that belongs here? If so, e-mail it to editorial@wirenet.org.

26 | WIRE JOURNAL INTERNATIONAL

South Korean cable contract goes to Habia

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Sweden’s Habia Cable, a high-end cable manufacturer, announced that it has further bolstered its position in the South Korean nuclear market with its latest contract.

A press release said that Habia Cable will supply Korea Hydro & Nuclear Power (KHNP) with nuclear safety grade cables for its new Shin-Ulchin 1&2 (APR 1400) nuclear power plants on the Korean east coast. Deliveries, it said, are planned to take place through an 18-month period starting in 2014. Habiatron Q class cables, it said, have been installed in all new Korean nuclear power plants built since the construction of Younggwang 5 & 6 in the late 1990s.

“We take great pride in winning this important contract in Korea as it confirms that our long term investments in the nuclear market are paying off,” said Habia CEO Carl Modigh.

Observed Micael Lindberg, vice president and head of the nuclear division at Habia Cable, “Korea’s nuclear industry is expanding fast and is one of the few countries besides China, Russia and India that is investing in the construction of new power stations. Our unique, safety class products are

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Habia Cable notes that it holds the environmental certification of the international standards institute IEEE (IEEE 383:1974) and testing to standard 383:2003 is pending with results expected by the end of 2012.

Malaysia to check imported steel wire rod Malaysia plans to investigate import of steel wire rods from certain countries.

Reports in Bernama and Steel Guru said that the government will initiate a preliminary investigation on the import of steel wire rods from Chinese Taipei (Taiwan), China, Indonesia, South Korea and Turkey. The Ministry of International Trade and Industry said in a statement that, “The government has determined that there was sufficient evidence of dumping, injury and a causal link.”

The investigation, the report said, was initiated following a petition for the imposition of anti-dumping duty on imports of steel wire rods from a domestic producer. The petitioner, it said, alleged that steel wire rods originating from the said countries were being brought into Malaysia at a price much lower than that in their domestic markets.

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AUGUST 2012 | 27

ASIAN FOCUS

ASIAN NEWS BRIEFS

PEOPLE

PEOPLE Amy Theobald has been named the global sales manager at T&T Marketing, Inc., effective July 1, 2012. For the past four years she has served T&T as an account manager in both the mid-Atlantic and southwest sales regions. In her new position, she will seek to improve T&T’s customer responsiveness, support account managers and product managers in mainAmy Theobald taining and increasing sales, and focus on growing T&T’s international customer base. She will continue to serve as product manager for masterbatches and concentrates. She has 16 years of experience within the plastics industry. Taking over Theobald’s southwest sales territory will be Royce Freitag. He worked for 13 years at Nexeo Solutions (formerly Ashland Distribution), most recently as a senior account manager.

He also served as a technical service representative with Ashland/General Polymers. He previously worked for 12 years at Hoechst Celanese, serving in quality control and as a technical service engineer in the HDPE business unit. Based in the U.S., T&T Marketing, Inc., provides sales, distriRoyce Freitag bution, and brokerage services to the wire and cable industry.

Gibbs Wire & Steel Company recently named Dale Porter as the new warehouse manager of its California service center. He has more than 20 years of general management experience having served as a retail manager at Stater Bros. Markets and as a department manager at Lowe’s Home Improvement Warehouses. Based in Southington, Connecticut, USA, Gibbs Wire & Steel is an ISO 9001:2008 certified distributor and custom processor of steel wire and strip.

U.K.-based Metalube Ltd. has named David Cole as sales manager.

He has more than 20 years of experience within the tube and wire drawing lubricants industry and is responsible for Metalube’s European Sales.

Based in Manchester, U.K., Metalube Ltd. specializes in tube and wire drawing lubricants, protective greases for overhead conductors and metal cutting fluids.

David Cole

The Elgin Fastener Group announced the recent appointment of Marty Goeree to the position of vice president of sales. He has more than 16 years of experience as a fastener industry executive, including at key management positions and at multiple locations with Fabory North America, Fabory CEE and Textron Fastening Systems. He holds B.S. degrees in geography, history and education from Mount Allison University in Sackville, New Brunswick, Canada, and he holds an MBA degree from Oxford Brookes University in Oxford, England. He has an extensive knowledge of the domestic and international fastener distribution networks that immediateMarty Goeree ly benefit the company’s sales efforts.

He replaced the former vice president of sales, Joe Hertz, who will continue to serve the Elgin Fastener Group as director of sales, reporting to Goeree while concentrating on sales management and maintenance of key accounts. Based in Versailles, Indiana, USA, the Elgin Fastener Group is comprised of seven leading domestic specialty fastener manufacturers.

OBITUARY Bobby Rowland, a longtime industry veteran, died at his home in Carrollton, Georgia, on June 24 at age 79. He began working for T&T Marketing in 1990 as the company’s fourth employee. He had a quiet demeanor, and when he spoke everybody listened, and he became known by his “northern partners” as the “Southern Gentleman.” He served the company as its southeast U.S. account manager and provided technical support. An inventor in the plastics field, he had developed several products during his tenure that are now sold commercially by T&T. He was still working for the company at the time of his death.

Rowland married his wife, Barbara, in 1952 just prior to

28 | WIRE JOURNAL INTERNATIONAL

his deployment to Japan as a radio operator in the USAF during the Korean Conflict. After serving four years he attended Southern Polytechnic State University, where he earned a degree in electrical engineering. He then joined Southwire Company, where he spent 29 years in technical services and development in the area of electrical wiring and plastic polymer engineering. During his long career in plastics his name was on many patents. He was preceded in death by his wife of 57 years. Survivors include his daughters Alice and Willa Beth; son Robert; and 11 grandchildren.

FIBER WATCH

FIBER WATCH Report: U.S. fiber optic cable market looks good for the next five years The next five years should be good for manufacturers of optical fiber cable declares a recent publication from IBIS World, Fiber Optic Cable Manufacturing in the U.S. Industry Market Research Report.

The press release about the report observes that “the fiber optic cable manufacturing industry has benefited from a rise in demand for fiber optic networks and fiber optic cable.” Consumers, it said, have increasingly demanded high-speed internet in their homes and on mobile devices, underpinning this trend.

“As a result, wireless carriers and cable providers are demanding fiber optic cable at increasing rates,” the release said, predicting that the next five years will bring higher revenue growth to the industry. “Consumer demand for high-speed internet on mobile devices will likely accelerate over the period, resulting in the widespread upgrade of wireless network services to compete for the consumer’s dollar. Manufacturers that have existing relationships with wireless carriers (or installers that contract with wireless carriers) will be in the strongest position going forward.”

The fiber optic cable manufacturing industry has had its share of challenges the past five years, with revenue anticipated to fall at an average of 1.8% per year to $1.9 billion in the five years to 2012, the release said. “This decline was largely due to recession-related cutbacks in infrastructure spending, Optical fiber should be glowing which resulted in a 28.7% decline in revwith potential based on IBIS World’s outlook for optical fiber enue in 2009. On the whole, though, the cable. industry has benefited from a rise in demand for fiber optic networks and fiber optic cable.”

Despite the recession, the industry was able to rebound quickly as the American Recovery and Reinvestment Act (ARRA) awarded government contracts and set forth incentives for broadband infrastructure development across the U.S., the release said. However, domestic manufacturers have had to contend with competition from foreign firms as imports have increased over the five years to 2012, the majority of those imports coming from lowwage countries such as Mexico and China, it said.

30 | WIRE JOURNAL INTERNATIONAL

“Fortunately exports have also grown aggressively over the past five years due to a weak U.S. dollar and growing demand for fiber optic cable in emerging economies,” IBISWorld Industry Analyst Nima Samadi said in the release. The fiber optic cable manufacturing industry has a medium-low level of concentration, and an increase in major company market share indicates that the industry is becoming more concentrated despite its growth phase, she said. At the same time, the industry is becoming increasingly globalized, with major companies including Optical Fiber Solutions, Corning Incorporated and AFL Telecommunications having operations in the U.S. and abroad. Conversely, smaller firms typically operate on a local or regional basis and lack sufficient resources to expand abroad or invest in product innovation, she said.

The report includes an executive summary, key external drivers, current performance, industry outlook, industry life cycle, major markets, supply chain, globalization and trade aspects, major companies, key statistics and more.

For more information, go to www.ibisworld.com or call tel. 800-330-3772.

U.S. to install a fiber optic cable link to Guantanamo Bay in Cuba According to published reports, the U.S. military plans to install a $40 million underwater fiber-optic cable to improve communications at Guantanamo Bay. The reports cited Army Lt. Col. Todd Breasseale, a spokesman for the Guantanamo military commissions, as saying that the goal is to bring the infrastructure of the naval base up to par with other government agencies. “It feels like the sort of dial-up Internet that we had in the 90s. “It’s a very limited bandwidth,” he said The cable, he noted, would run 800 miles from Guantanamo Bay to South Florida and could start operating within two years.

Cuban authorities have been notified about the project, and the survey ship USNS Zeus is expected to arrive at the naval base in upcoming weeks, Breasseale said. He noted that technicians now have to constantly reroute bandwidths depending on the needs of the various organizations based in Guantanamo.

“It massively degrades the systems when you have to put your work product on hold,” Breasseale said. “This is really going to cure a lot of ills.” The cable project, he explained, is meant to serve the naval station for years to come, but is not an indication that the detention center, which currently holds 169 detainees, will remain open indefinitely. “We have plans to close the detention facility,” he said. “That remains our goal.”

The fiber-optic cable project has been included in the fiscal 2013 budget and needs approval from Congress, the articles said.

FASTENER UPDATE

FASTENER UPDATE Total 2011 fastener output in mainland China said to been up by nearly 10% In 2011, the total output of China’s fastener was up 9.7% to 6.8 million tons from the prior year, with sales up 10% to 66 billion yuan, driven by the revenues of some 200 enterprises that reported sales exceeding more than 100 million yuan.

According to a report in chinafastener.com, steel fasteners exported from mainland China in 2011 respectively grew by 13.95% and 27.56% to 2.589 million tons and US$4.664 billion year-on-year. The export sales, it said, accounted for 38% of the total sales, which reflected the proportion of domestic sales and export sales “becoming more and more reasonable.”

Steel fastener exports to the EU were held back by high anti-dumping duties, but export products like nuts saw a jump growth, the report said. Steel fasteners exported to the U.S. increased by 13.3% while exports to emerging markets like Russia, India, Brazil, and South Africa, and especially Eastern Europe, saw large growth on volume and value, it said.

In 2011, fasteners imported by mainland China saw a slight increase of 0.39% and 2.41% to 264,000 tons and US$2.94 billion respectively in comparison with 2010, the report said.

Herndon Products wins a multi-million federal contract to supply fasteners Herndon Products announced that it recently received a prime contract award from the Defense Logistics Agency (DLA) Troop Support, supporting the Aviation Demand and Supply Chain Strategic Fastener Initiative.

A press release said that Herndon Products was one of four winners of this contract for Federal Stock Class 5305, the first major contract award of its kind. The indefinite quantity contract award was valued at $3.8 million for a two-year base contract, with three one-year options for extension, it said. It added that the federal government identified 44,804 items that could be added to the contract for a total value of $77.9 million.

“This is exactly what we do every day,” Herndon Products President and CEO Scott Herndon said in the release. “It’s a perfect fit for our technology and procurement processes.”

Responding to the DLA’s request for bids on 1,984 items, Herndon Products bid on 1,958 of them. The company won the right to supply 1,142 of the 1,318 items (86.6%) that DLA ended up awarding to the four winners.

The release said that the contract follows the company’s winning of another prime contract award in April. That award, it said, from the Defense Logistics Agency, Land and Maritime operations, calls for the company to manage the Industrial Product-Support Vendor (IPV) program at the Tobyhanna Army Depot. Herndon Products was selected 32 | WIRE JOURNAL INTERNATIONAL

from a 14-month evaluation in an unrestricted competitive procurement among major defense contractors, it said.

The contract, the release said, was appropriated as part of the Fiscal 2012 Defense Working Capital Funds, with a funding limit of $56 million.

Taiwan exports of fasteners in 2011 resulted in record, up more than 11% Taiwan’s export of fasteners set new records in 2011, which saw export volume increase by 11.14% to 1.42 million tons, while export value grew by 23.61% to US$3.97 billion year-on-year.

A report in chinafastener.com said that the ailing European market had dragged some, with Taiwan’s fastener export to the EU dropping to 111,000 metric tons (mt) for the first quarter of 2012, down from the last quarter of 2011 (114,000 mt), which itself had been down 7.3% to the third quarter of 2011 (123,000 mt). However, it said, export value grew by 4.7% “and the unit price stood on the high point of 2.803 dollars.”

The U.S. imported 520,000 mt of fasteners (36.6% of the total) from Taiwan in 2011, ranking as the largest importer, followed by Germany, Netherlands, Japan, and U.K., which took 10.2% (145,000 mt), 6% (86,000 mt), 4.5% (64,000 mt) and 4.2% (60,000 mt) respectively, the report said. The unit price exported to Japan topped the highest level and reached 3.4 dollars/kg; while the unit price to other four countries was among 2.5 to 2.8 dollars/kg, it said.

Taiwan, the reported noted, seldom imports fasteners, with its annual import volume estimated from just 20,000 to 30,000 mt.

Alcoa Fastening Systems wins improvement award from Airbus Alcoa Fastening Systems (AFS) reports that it has received a Bronze Award from Airbus for outstanding performance in its Supplier Quality Improvement Program.

A press release said that the award, based on selections of the company’s top tier suppliers, recognizes supplier improvement, quality, on-time delivery and sustainability performance. AFS provides Airbus with fasteners for all of their major programs including the A320, A330, A340, A350, A380 and A400M models.

“We are honored to receive this award from Airbus,” said Craig Brown, vice president global aerospace customers and marketing for AFS. “This recognition shows that our customers appreciate the dedication of our manufacturing operations, as well as that of our quality, engineering, logistics and sales organizations. ” Alcoa Fastening Systems, a business unit of Alcoa, is a global supplier of fastening systems that include specialty fasteners and more for aerospace and industrial applications.

WAI

NEWS

WAI NEWS

Member Relations Committee updates membership drive, plots action plan WAI’s Member Relations Committee met on Friday, July 20, at the Association’s headquarters in Guilford, Connecticut, to assess membership activity, consider new initiatives and lay out further plans.

The meeting, headed by Tom Heberling of Southwire Company and Tim Wampler of General Cable, covered a range of topics, from encouraging companies to sign up more employees, to better explaining the value of membership, to efforts to retain existing members.

Committee members will be contacting companies to talk about membership. Efforts had already begun, but not on a full-fledged basis. Explained Heberling, “We wanted to get our own house in order first,” he said, noting that Southwire, which now has 154 WAI members, has done just that.

Earlier, WAI 1st Vice President Richard Miller, Southwire Company, elaborated on why the company has so many members on the list that begins on the next page. “The WAI serves the industry we live and work in, and I believe in supporting the Association because its mission directly ties

Member Relations Committee co-chairs Tom Heberling, Southwire Company (l) and Tim Wampler, General Cable, covered a lot of topics at the meeting.

Wampler said that General Cable signed up 10 employees in the last few weeks and that “50 or more are coming.” He said that some of his peers had asked about the memberships. “When I explained to them how much they got out of the association, they fell right in line.”

Per the committee’s request when it met during the WAI Operations Summit and Wire Expo 2012, the WAI has begun keeping a weekly scorecard and there was a lot of focus at the meeting on retention.

WAI staffers updated committee members on different initiatives. Chuck Szymaszek showed committee members a new on-line membership sign-up system. Janice Swindells provided new brochures outlining the benefits of the Member Relations Committee members met with staff and guests at Association and Marc Murray disAssociation headquarters to review a list of companies that will be cussed an expanded webinar series. approached during WAI’s membership recruitment campaign.

Wampler said that it was important to get the message out as to what the WAI could do, especially for first-year members who are the in with our livelihoods. It would be easy for Southwire to ones most likely to drop out. They need special attention, to have just one or two members at each of our plants, but be immersed in the Association to establish a meaningful there are a lot more Southwire employees who would benerelationship, he said. fit by being members. They can be plant managers or engiCommittee members covered a lot of topics, but stressed neers or in quality control or maintenance or safety or even the need to make direct contact with key people at the front office, but each one is part of the reason for companies that should have more WAI members.

Southwire’s success. We want them to take pride in what Miller said that he has made calls on behalf of the WAI, they do, but also in the Association that represents them including one to a well-known cable company executive through its trade shows, educational programs, networking who replied that he understood what he wanted him to do. opportunities and more. I’d also like to see more companies “I talked to him for five minutes anyway.” He added that follow our lead because the stronger the Association is, the there is lots of misinformation, such as the belief that if a more it can do for its members. It’s giving back and helping company has one member, then all employees are members. yourself at the same time.”

A follow-up meeting is being planned for October.

34 | WIRE JOURNAL INTERNATIONAL

The following individuals recently joined Wire Association International.

Jonathan B Allen Electrical Engineer Southwire Co

James Hill Electrical Engineer Southwire Co

John Dognazzi Business Development Engineer Sikora International Corp

Ryan C Hulsey Industrial Engineer Southwire Co

Douglas G Drysdale Product Design/Appl Nexans Canada Inc Eddie Everson Materials Manager Southwire Co

Mike Johnson Quality Manager Southwire Co Wellington E Kendall, III Engineer Southwire Co

Chris McBrayer Environmental Health & Safety Manager Southwire Co Dion L McCraw Shop Supervisor Southwire Co Rick McGathy Power Cable/Bare Wire Dept Mgr Southwire Co Karla C McGuire Purchasing Agent REELEX Packaging Solutions Inc

Scott Fields Department Manager Southwire Co

Hai T Lam Engineer Southwire Co - Forte Power Systems Inc

Steven Ford Materials Manager Southwire Co

Taylor B Latham Industrial Engineer Southwire Co

Greg L McKibben Senior Environmental Manager Southwire Co

Miles K Brupbacher Industrial Engineer Southwire Co

Steve D Foust Quality Sys Planning Mgr Leggett & Platt Wire Group

Jeffery K Lawrence Management Representative Elken, Inc

David McLendon Engineering Manager Southwire Co - Forte Power Systems Inc

Lucretia L Burt Sales Administration Leggett & Platt Inc

Greg S Gable Production Planner Southwire Co

Scotty Joe Ledbetter Process Engineer Southwire Co

Veerag Mehta Director Technology Polymer Dynamix LLC

Cy Butterworth Manufacturing Engineer Southwire Co - Forte Power Systems Inc

Tyler B Gibson Industrial Engineer Southwire Co

Joe Long Materials Manager Southwire Co

Charlie Miller Maintenance Manager Southwire Co

Ryan T Goad Safety Manager Southwire Co

Garan A Mason Operations Manager Southwire Co

Laine Mitchell Planner Southwire Co

Joshua K Grooms Industrial Engineer Southwire Co

John D Mattingly Engineer Southwire Co

Jon M Moon Industrial Engineer Southwire Co

Steve Henderson Operations Southwire Co

Jesse Mayfield Engineer Southwire Co

Ronnie Moore Mechnical Designer Southwire Co

Danny L Henderson Process Engineer Southwire Co - Building Wire Products

Cheryl McBrayer Quality Manager Southwire Co - Forte Power Systems Inc

Steven D Morris Manufacturing Manager Southwire Co

Natalie R Henley Human Resource Specialist Southwire Co

Keith McBrayer Quality Assurance Department Manager Southwire Co

Jarrod Basham Operations Manager Southwire Co Brandon R Bennett HR Manager Southwire Co

Eli Clanton Manufacturing Engineer Southwire Co - Forte Power Systems Inc George M Clark Purchasing Manager Southwire Co Viviana Coello-Wilson Marketing Manager Lubrizol Corp Chris Coomes Engineer Southwire Co Paul M Crafton President Consolidated Eng Co Brian Davis Bldg Wire Dept Mgr Southwire Co

Danny V Henry Quality Assurance Manager Southwire Co

Rodrigo O’Byrne Condusal S A De C V Blair L Parker Department Manager Southwire Co Charles A Pearce Senior Production Manager Southwire Co AUGUST 2012 | 35

WAI NEWS

Dustin Devine Operations Southwire Co

WAI NEWS

Wesley Robinson Process Engineer Southwire Co - Forte Power Systems Inc Scott Roulaine Materials Engineer Southwire Co - Forte Power Systems Inc

(continued)

Srikanth Sai Senior R&D Engineer Heraeus Materials Singapore Pte Ltd

Troy D Skidmore Technical Sales Manager Encore Wire Corp

Mark E Warren Energy Materials Manager Southwire Co

Kristi R Smith Human Resources Manager Southwire Co

John T Whitaker Process Engineer Southwire Co

Jimmy D Tarpley Qte Analyst Southwire Co

Doug Wigginton Production Manager Southwire Co

Ben M Thornton Electrical Engineer Southwire Co

Tyrone Wilkerson Training Manager Southwire Co

Charelle Peterson Engineer Southwire Co

Donnie Sanders Operations Superintendent Southwire Co

Jared B Pointer Southwire Co - Forte Power Systems Inc

Chris Tucker Process Engineer Encore Wire Corp

Jason Wilkins Engineering Manager Southwire Co

Pete E Seiler Maintenance Supervisor Southwire Co

Nathan Pongetti Controller Southwire Co

Rick Vascotto VP Sales & Marketing Nexans Magnet Wire

Donald W Sims Maintenance Supervisor Southwire Co

Nathan Ward Shipping Supervisor Southwire Co

Kenneth G Williamson Safety & Environmental Manager Southwire Co - Forte Power Systems Inc

Janet S Rainford Dir Inside Sales & Mktg Nexans Magnet Wire

36 | WIRE JOURNAL INTERNATIONAL

Dave Windom Maintenance Manager Southwire Co - Forte Power Systems Inc

Dr. Sitaram Rampalli’s June 21 webinar, Flame-Retardant Polymers for Wire and Cable Applications, drew 26 attendees from 16 companies.

During his hour-long webnar, Dr. Rampalli, president and principal consultant of U.S.-based Polyplast Consultants International (PCI) Inc., explained how to choose the proper flame-retardant polymers, using a systematic approach to the selection and evaluation of polymers for a variety of applications.

He said that demand continues to increase for flame retardants, but the challenge is that there is no “one-size-fitsall� formula for selecting Dr. Sitaram Rampalli covered the basics flame-retardant of flame-retardant polymers in his June polymers for 21 webinar. wire and cable

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applications. Some of the key factors that must be considered include the type of cables, where and how they are used, fire codes and disposal, he said.

Rampalli provided further details in response to two questions, one as to whether today’s standards and tests may either be updated or be in a development stage that may impact the industry, and another as to how cable manufacturers can increase their in-house expertise in the area of polymers.

WAI webinars are free for members, $55 for others.

Update: Interwire 2013 booth sales As of press time, WAI Sales Director Robert Xeller reports that some 90,000 net sq ft of exhibit space have been sold for Interwire 2013, to be held April 23-25 in Atlanta, Georgia, USA. That figure represents 90% of the available booth inventory, which now includes more than 200 exhibiting companies, he said. He added that good booth locations are still available, and that the floor plan can be expanded if need be.

Total attendance at Interwire 2011 was 4,022, up 19% from the 2009 event in Cleveland, Ohio, USA. For more details on exhibiting at Interwire 2013, contact the WAI’s sales staff at sales@wirenet.org, or call tel. 203453-2777.

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WAI NEWS

Rampalli webinar on polymers draws more than two dozen participants

CHAPTER CORNER

CHAPTER CORNER 3 WAI chapters name winners of their college scholarship programs A total of six scholarships were awarded by three WAI chapters, including one from the Midwest Chapter, two from the Southeast Chapter and three from the New England Chapters.

The programs are similar yet not identical, although for each chapter the applicant must be the son or daughter of a chapter member who is in good standing. For more details on how to apply, go to the chapter page at www.wirenet.org.

Below are the winners of the 2012 scholarships.

Midwest Chapter Jason DeGrado is the son of Jim DeGrado, general manager of Worth Steel & Machinery. He will be attending Purdue University to study psychology.

Matthew Fedor

Max Karsok

William Hammontree is the son of Joseph Hammontree, vice president of Temple Terrace Industries. He is currently studying mechanical engineering at Florida College.

New England Chapter Aideen Hanlon is the daughter of Brian Hanlon, general manager of Hueson Corporation. She will be attending the College of Saint Rose to study communication sciences and disorders.

Matthew Fedor is the son of Tony Fedor, production manager, cable, at Times Microwave Systems. He will be attending Western New England University to study accounting and business, and will also be pitching for the school’s baseball team.

Jason DeGrado

Meghan Kos

Southeast Chapter Meghan Kos, is the daughter of Mike Kos, operations manager of CNA Technologies. She is currently studying education at the University of North Carolina Chapel Hill.

William Hammontree

Aideen Hanlon

38 | WIRE JOURNAL INTERNATIONAL

Max Karsok is the son of William Karsok, production applications engineer at W. Gillies Technology. He will be attending Bryant University to study business.

A good time was had by all at the 2011 Midwest Chapter golf outing Not every shot may have been straight and true, but we have been assured that a good time was had by all at the Midwest Chapter’s 10th Annual Golf Tournament.

It was a classic day for the foursome of Ben Walley, Jim Hoffman, Nick Harris and Joe. Best. The Classic Die Service team scored 65 (seven under par) to take first place.

Other winners included the Longest Drive: Tony Iuliano, CASMI; and the three Closest-To-The-Pin winners: Bob Bender, Worth Steel & Machinery; Paul Zollinger, BAE Systems and Suzie Mullins, A-1 Wire Tech.

“It was a picture perfect day for golf on Friday,” said event Chairman Kevin Sopczak. “We saw a last minute surge in sign-ups, and we fielded some 60 golfers. That included a threesome of golfers from CASMI, who attended to support our cause and to promote their upcoming SpringWorld Trade Show in Rosemont this fall.”

Observed Tom Moran, “You couldn’t have asked for a

2 down, 3 more golf tourneys to go for WAI chapters in 2012 Above is the wrapup on the WAI’s Midwest Chapter’s 10th Annual Golf Tournament and the Ohio Valley Chapter’s 10th Annual Golf Tournament was slated to be held Aug. 2, in Solon, Ohio, USA, but there are still three more golf outings left this year.

Up next will be the New England Chapter’s 18th Annual Golf Tournament, to be held Sept. 10, in Ellington, Connecticut, USA, at the Ellington Ridge Country Club.

For more details on this event, call WAI’s Anna Bzowski at tel. 203-453-2777, ext. 126, or abzowski@wirenet.org.

The New England event will be followed by The Vannais Southeast Chapter 11th Annual Golf Tournament, to be held Oct. 18 in Conover, North Carolina, USA, at the Rock Barn Golf & Spa. The final outing of the year will be the Western Chapter’s 12th Annual “Wild West Shootout” Golf Tournament, to be held Oct. 22, in Rancho Palos Verdes, California, USA, at the Los Verdes Golf Course.

Each event offers a range of sponsorship opportunities for companies that would like to both support the event and get a bit of exposure. For more details on such opportunities, as well as the cost for playing and registration, e-mail WAI’s Steve Fetteroll at sfetteroll@wirenet.org or visit the individual chapter pages at www.wirenet.org.

Schedule set next month for Poland Chapter’s 9th technical seminar The schedule for the Poland Chapter’s Sept. 20-22 technical seminar has been set for the event’s return to the Antalowka Hotel in Zakopane, Poland, marking the fourth such staging.

Chapter President Jan Pilarczyk said that participants will include presenters of invited papers and attendees from some 40 drawing plants and institutions from Poland, Italy, Germany, and Czech Republic, among others. The program,

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CHAPTER CORNER

more perfect day. Certainly I’m talking about the weather.

My golf game could use significant help. The turnout was good and the opportunities for networking with suppliers and customers as always, was great.”

The chapter wished to thank the sponsors for the event: Closest-to-the-Pin (Classic Die Services, Lloyd & Bouvier and Suzuki Garphyttan); ong Drive (Charter Steel and Lloyd & Bouvier); and Corporate Hole (A-1 Wire Tech, Classic Die Services, Fort Wayne Metals, Krueger Steel & Wire, Lloyd & Bouvier, Micro Products, National Standard, Omni Source, Premier Wire Die, Suzuki Garphyttan, United Scrap Metal and Worth Steel and Machinery.

CHAPTER CORNER

“High Carbon Steel Wires and Ropes: Technology and Properties,” will include the presentations, tabletops, an awards ceremony, and more.

Registration for the seminar is from 4 pm to 6 pm on Thursday, Sept. 20, followed by a banquet that will include the awarding of the Prof. M. Schneider Prize. The seminar starts at 9 am on Friday, Sept. 21, with the opening ceremony. With Pilarczyk serving as moderator, the technical sessions run from 9:10 am to 11:30 am, including presentations by Prof. Etienne Aernoudt (Drawing Induced

At the 2011 conference, Kis Wire’s G. Bae presents his technical paper. Sitting (l-r) are session moderators Prof.

Kazunari Yoshida and Prof. Zbigniew Pater.

Structural and Mechanical Anisotropy); Dr. Nicholas Nikoletopoulus (Wire Association International: its activity for development of the wire industry); Prof. Bogdan Golis (Mechanical descaling of high carbon steel wire rods) and Dr. Sylwia Wiewiórowska (Theoretical and experimental analysis of processes of drawing of new generation TRIP wires). Following a break, technical sessions resume from noon to 5 pm, moderated by Chairman Prof. Etienne Aernoudt. The presentations will be by Dr. Zdzisław Konopka, Dr. Krzysztof Konopka (Induction patenting of high carbon steel wires); Prof. Tadeusz Knych, Dr. Andrzej Mamala, Dr. Beata Smyrak and Dr. Piotr Uliasz (Selected material, constructional and operational problems in electrical overhead transmission systems); Prof. Pilarczyk (Recent

research concerned with steel wire drawing carried out at Czestochowa University of Technology); Prof. Zbigniew Muskalski (Some aspects of theory and technology of drawing of high carbon steel wires); Roman Glik (Current marketable position of “Polskie Liny” Sp. z o.o); and Eng. Maciej Górak (Presentation of drawing machines producer – GCR Company and of drawing lubricants producer – Lubrimetal company).

There will be a break for lunch with dinner held later that night. Closing ceremonies will be held Saturday, Sept. 22, at 9 am.

In 2011, WAI’s Poland Chapter, working with the Institute of Modeling and Automation of Plastic Working Processes of Czestochowa University of Technology, organized a successful three-day conference at the Antalowka Hotel. There were 51 presentations in four sessions (ferrous, nonferrous, electrical and special products) and a poster session. In addition to Poland, scheduled speakers came from Sweden, Spain, Japan, South Korea, U.S., Russia and the Czech Republic. 109 participants from more than 40 institutions and companies came for this conference. Among them were representatives from 11 technical universities and research institutes (Poland’s AGH University of Science and Technology, Czestochowa University of Technology, Institute for Ferrous Metallurgy, Institute of Nonferrous Metals, Silesian University of Technology, Lublin University of Technology; Sweden’s Orebro University, Technical University of Madrid, Spain; UPM, Japan Tokai University, Russia Moscow Institute of Steel and Alloys, South Korea’s KISS Wire Ltd., and The Technical University Ostrava, Czech Republic).

Beyond the technical program, the 2011 event included an opening reception and a gala dinner with folk music as well as special lectures presented by 2011 Schneider Memorial Award recipients Prof. Kazunari Yoshida, from Tokai University, Japan, and Eugeniusz Filipczyk, past president of Drumet, Poland.

For more information on the 2012 event, contact Sylwia Wiewiorowska at wiewior@wip.pcz.pl; tel. 48-500-020 676 (mobile).

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INTERWIRE 2013 | THE LARGEST WIRE AND CABLE MARKETPLACE IN THE AMERICAS.

April 23-25, 2013 | Georgia World Congress Center | Atlanta, Georgia, USA

INTERWIRE 2013 LEADING WIRE BUSINESSES IN THE AMERICAS. WHY INTERWIRE? When industry professionals look for new wire and cable technology they choose Interwire, the benchmark for wire business in the Americas.

Information is exchanged at Interwire. Machinery is debuted, reviewed, and sold at Interwire. And the promise of international networking on the Americasâ&#x20AC;&#x2122; stage continues to excite visitors to this vital marketplace.

Location: Atlanta, Georgia.

Interwire returns to the city of its origin where it was introduced in 1981.

Compact: 3 full days of exhibits.

Interwire 2013 offers a concentrated show schedule.

Operating equipment.

Interwire is a machinery show. Visitors will see operating equipment.

Renewed energy.

Attendance at Interwire 2011 surged with a 19% uptick. Visitors came from 53 countries. More than 400 companies exhibited making Interwire the largest trade show of its kind in the Americas for the wire and cable industry.

Special industry theme days to be announced.

Look for presentations, technical papers, and executive discussions to orbit around three central themes related to operational excellence in the manufacture of wire and cable. Specific topics to be announced.

Fully supported.

Show management continues to work with allied organizations, supporting sponsors, and educational supporters to interest a growing number of international participants in the show. Event news is communicated to Wire Journal International readers in 108 countries worldwide.

Learn more about exhibiting and speaking opportunities at www.wirenet.org.

The Wire Association International, Inc. 1570 Boston Post Road | P.O. Box 578 | Guilford, CT 06437-0578 USA Telephone: (001) 203-453-2777 | Fax: (001) 203-453-8384 | www.wirenet.org

EXHIBITING COMPANIES — As of July 2012 — George Evans Corp.

Evolution Products Fabritex Inc. Filtertech Inc. Fine International Corp.

Fisk Alloy Wire Inc. Flymca & Flyro FMS USA Inc. Foerster Instruments Inc. Fort Wayne Wire Die Inc. Frontier Composites & Castings Inc. Fuhr GmbH & Co. KG Gauder Group Inc. GCR Eurodraw SpA Gem Gravure Co. Inc. Genca GMP Slovakia sro Guill Tool & Engineering Co. Guney Celik Hall Industries Handuk Ultrasonic Hangzhou JR Exhibition Co. Ltd. Heacock Metal & Machine Co. Inc. Heany Industries Inc. Hearl Heaton - Pentre Group Heatbath Corp.

Heraeus Noblelight LLC Heritage Wire Die Inc. Howar Equipment Huestis Industrial ICE Wire Line Equipment Inc. IDEAL Welding Systems iim AG Measurement & Engineering INHOL LLC InnoVites Cable ERP Software International Wire Machinery Association (IWMA) InterWire Products Intras Ltd. IWG High Performance Conductors Inc. Joe Tools Inc. Keir Manufacturing Inc. KP America Inc. Lämneå Bruk AB LaserLinc Inc. Leggett & Platt Wire Group Leoni Wire Inc. Lesmo Machinery America Inc. Lloyd & Bouvier Inc. Lubrimetal Corp.

The Lubrizol Corp.

LUKAS Anlagenbau GmbH Magnetic Technologies Ltd. Maillefer SA Manner Plastics LP Markem-Imaje USA Mathiasen Machinery Inc. Messe Düsseldorf North America MFL USA Service Corp. - Frigerio The MGS Group MGS Manufacturing Inc. Micro Products Co. Microdia USA Mid-South Wire Morgan-Koch Corp.

Niagara Composites International Niehoff Endex North America Inc. Northampton Machinery Co. (USA) Numalliance North America Oklahoma/Iowa Steel & Wire OMA USA Inc. OMCG North America Inc. Paramount Die Co. Parkway-Kew Corp.

Pave Automation Design Phifer Wire Inc. Plas-Ties Co. PolyOne Polytec Inc. Precision Die Technologies Inc. Pressure Welding Machines Ltd. PrintSafe Promostar srl Properzi International Inc. QED Wire Lines Inc. QUEINS Machines GmbH Radyne Corp.

Rainbow Rubber & Plastics Rautomead Ltd. Redex SA Reel Options by Vandor Corp.

Reel-O-Matic Inc. RG Attachments Ltd. RichardsApex Inc. Rosendahl Nextrom Technologies Roteq Machinery Inc. S&E Specialty Polymers SAMP USA Inc. Shanghai Pudong International Exhibition Co. SIKORA International Corp.

SIMPACKS Sivaco Wire Group Sjogren Industries Inc.

Smeets SA Joe Snee Associates Inc. Sonoco Reels SPX Precision Components FENN Division Strecker USA T & T Marketing Inc. Talladega Machinery & Supply Taubensee Steel & Wire Co. Taymer International Inc. Tecnoherramental SA de CV Teknikor Teknor Apex Tensor Machinery Ltd. Traxit North America LLC Troester GmbH & Co. KG Tubular Products Co. Tulsa Power Inc. United Wire Co. Inc. US Synthetic Wire Die Reel Options by Vandor Corp.

Vollmer America Inc. WAFIOS Machinery Corporation Stolberger Inc. dba Wardwell Braiding WCISA - Wire & Cable Industry Suppliers Association Web Industries Weber & Scher Mfg. Co. Inc. Windak Inc. Wire & Cable ASIA Magazine Wire & Cable Technology International Wire & Plastic Machinery Corp.

The Wire Association International, Inc. Wire Journal International Wire Lab Co. Wire Machine Systems Inc. WireCo WorldGroup WiredIn USA Witels Albert USA Ltd. Woodburn Diamond Die Inc. Worth Steel & Machinery Inc. Zumbach Electronics Corp.

INTERWIRE 2013 | THE LARGEST WIRE AND CABLE MARKETPLACE IN THE AMERICAS.

Ace Metal Inc. AEB International Inc. AIM Inc. All Forming Machinery Inc. Amacoil Inc. Amaral Automation Associates American & Efird Inc. Anbao Wire & Mesh Co. Ltd. AXIS Computer Systems Inc. Aztech Lubricants LLC B&H Tool Co. Bartell Machinery Systems LLC Bekaert Corp.

Bergandi Machinery Co. Besel Basim San Tic Ltd. Sti Beta LaserMike Blachford Corp.

Bogimac Engineering Boxy SpA Breen Color Concentrates Inc. Butt Welders USA Caballe SA Cable Consultants Corp.

Canterbury Engineering Co. Carris Reels Inc. Cemanco LC Central Wire Industries Ltd. Chase Wire and Cable Materials Cimteq Ltd. Clayton Industries Clinton Instrument Co. CM Furnaces Inc. CMEC International Exhibition Ltd. Collins & Jewell Co. Inc. Commission Brokers Inc. Condat CONDUCTIX WAMPFLER Conneaut Industries Inc. Cortinovis Machinery America Inc. CPA Wire Technology GmbH Davis-Standard LLC Die Quip Corp.

Domeks Makine Ltd. Sti Ebner Furnaces Inc. Electron Beam Technologies Inc. Enercon Industries Engineered Machinery Group Inc. Er-Bakir Elektrolitik Bakir Mamulleri A.S. ERA Wire Inc. Esteves Group USA Etna Products Inc. EuroWire Magazine

EVENT PREVIEW The opening ceremony at wire China 2010. Organizers are hopeful that the 2012 staging will enjoy similar success.

wire China: organizers sees widespread support Organizers have high expectations for the 5th All China International Wire & Cable Industry Trade Fair, better known as wire China 2012, which with its sister show, Tube China 2012, will be staged concurrently Sept. 25-28 in the Shanghai New International Expo Centre in China.

A press release from Messe Düsseldorf, which jointly organizes the event along with the Shanghai Electric Cable Research Institute (SECRI), said that as of the end of May, “exhibitor recruitment has concluded with encouraging results.” A total of 752 companies from 26 countries have confirmed their participation in wire China 2012,” it said, adding that, “The exhibitor promotion went smoothly, and booths of the two exhibitions have almost been booked up.”

The two exhibitions are estimated to occupy 7.5 halls, covering a total of 85,000 sq m, with some 1,500 exhibitors expected to participate, the release said. The event will host national or regional pavilions from Germany, Italy, U.S., France, Austria, South Korea, Japan and the Taiwan region.

“Moreover, this year the South African Wire Association will organize a delegation to participate in wire China 2012 for the first time, sharing the booming business opportunities of China wire and cable industry.”

The collective exhibits will present and/or display wire manufacturing and finishing machinery, process technology tools, auxiliary process technology materials, materials, special wires and cables, measuring and control technology, test engineering, and specialist areas, the release said. The event outlook depends on the development outlook for the industry, and the “attitude of the major manufacturers (shows) great confidence and expectations of the industry for China wire, cable and tube markets,” it said. It noted that since 1996, China has held the top position in the world for 44 | WIRE JOURNAL INTERNATIONAL

steel output, and that in 2011, its crude steel production was 46% of the world’s total.

Based on the success of past editions, the wire and tube events are “expected to achieve a new zenith this year,” the release said. “wire & Tube China 2012 will continue to be a perfect platform for companies to show strength, for industry insiders to learn new technologies, new products and market trends, and for in-depth academic exchanges.”

For more information, contact Messe Düsseldorf North America, tel. 312-781-5180, fax 312-781-5188, info@mdna.com, www.mdna.com.

Exhibitor comments FLYMCA, which specializes in designing and producing rotating machines for the wire and cable industry, will exhibit at wire China, but it is also pleased to invite worldwide customers to a presentation in our new production facilities that offer more than 5000 sq m for machinery production as well as a used machinery warehouse for our sister company FLYRO. The company recently commissioned an innovative heavy-duty SZ laying-up line for submarine/ offshore power cables to a key European cable manufacturer that will produce medium- and high-voltage cables. This unique, high-efficiency machine can run at speeds up to 20 m/min. FLYMCA offers other innovative lines, including: a high speed and efficient 54 rigid strander with automatic bobbins loading system; a bow cabler for reels with a diameter to 1600 mm; a complete drum-twisting line with takeup 2,5 m/20 ton; and a special 30-bobbins tubular stranding line for OPGW, including a bulk head. Contact us at www.flymca.com and www.flyro.es or rvc@flymca.com.

Long active in the Chinese market, the Gauder Group, known for its Pourtier and Setic brand names, looks forward to displaying its latest European-produced technology.

Pourtier develops comprehensive solutions to produce all kinds of power cables, including HV and EHV, from overhead cable to insulated cable, AC or DC. Setic offers complete solutions to produce LAN cables with enhanced performances as well as double-twist bunchers and stranders.

It will display a cost-effective version of its well-known double-twist buncher. Gauder Group China has made rotating machines from Changzhou since 1999, providing European quality with local services at competitive levels.

Daloo, part of the Gauder Group, provides simple and reliable cable machinery designed in Europe and made to strict quality control in China at affordable prices. Gauder Group.

Our reason for participating is twofold: to drum up business in the region, and to underline our commitment to the Chinese market, in particular, and to our customers and prospective customers in Asia, in general. We see the Chinese market as a growth area for a long time. The Chinese economy may stumble, but it has enough ballast to Ali Shehab see it through recovery very quickly.

We will display CableBuilder, our cable design and quotation software for all types of cables, generating datasheets and drawings and costing them too.

Also, our InnoVites cable ERP software that is based on Microsoft Dynamics AX, and designed and supplied by our partner InnovVites. Ali Shehab, Cimteq Ltd. China is an extremely significant market for our industrial lubricants. In 2005, Metalube (Shanghai) Ltd. was estab-

lished with sales offices in Shanghai and Dongguan. We will have key staffers from there as well as from our home office. Also exhibiting will be DLF, one of our key distribution partners in China. Our company has undergone some major changes in the past year, opening another office in India and revamping our corporate identity brochures as well as a new website. The stand will reflect this evolution.

Douglas Hunt, commercial director, Metalube.

We are active in some very specific and technical niches in China and want to further diversify and increase our commercial network in this region.

China’s wiredrawing activity is very important and we forecast an increasing growth on this sector. CONDAT will present its extensive range of lubricants for wiredrawing of high-carbon steel, including a new offer for PC Pascal Cossu strand production (latest surface precoatings meeting both high performance and environmental standards) and lubricants for wet drawing focused on high tensile galvanized, phosphate-coated, etc. Pascal Cossu, sales area manager, CONDAT. For our butt welders, China continues to be a strong market, so we are returning to wire China for the exposure and as a medium to connect with potential buyers, specially from Southeast and South Asia, and for meetings with our international reps in China and other countries that will be at the show.

Since enhancing our brand recognition in this region is important, the show William Banks is a good venue for us and we expect positive results. We will display a Micro-Weld ceramic fusion butt welder that offers clean burr-less butt welding of stranded conductors (copper and aluminum) in disposable ceramic sleeves. Micro-Weld’s Model HP-1 (for 10 sq mm to 120 sq mm conductors) will be displayed. William Banks, president, Micro Products Company.

GCR Eurodraw welcomes the opportunity to display and provide further informations about its collective technology to attendees at wire China 2012. We see the Chinese market of machinery for steel wire processing for wires, cord and ropes still quite strong because of the continuing program of investments in construction, buildings, roads, bridges, highways, transport and material handling. Although the local producers offer an ever-larger range of machines at low prices, the key wire processing equipment designed in the EU is preferred for its quality, reliability and performance.

Enrico Depaoli, director, GCR Eurodraw.

AUGUST 2012 | 45

EVENT PREVIEW

Since the mid-1960s, SKET has supplied machinery and equipment to China’s cable and steel wire rope industries.

We have seen its development into the world’s largest manufacturing center. We have enjoyed close relationships in our many partnerships with Chinese companies that have contributed to this dynamic growth with their efforts, and we view the future of our business activities there with great optimism. We will showcase a new generation of central stranders, featuring a 500 kg Al wire bobbin capacity; special design large planetary stranders/closers for submaGeorg Godau rine cable; new large double-twist bunchers for producing multiple layer strands up to 12 mm; and a long high-speed tubular strander and large cage-type stranding machine for making offshore and mining ropes.

Georg Godau, general manager, SKET GmbH.

EVENT PREVIEW

Alpha list of exhibitors Below is an alpha listing for exhibitors outside mainland China provided by the organizers. For more details, go to www.wirechina.net and see the show program at the event.

ALMT Corp AESA SA Agility Fairs & Events GmbH AlphaGary Corporation An Chen Fa Machinery Co, Ltd ASABA Co, Ltd ATE ApplTermoelectroniche Srl August Strecker GmbH & Co Besel Basim San Tic Ltd Sti. Beta LaserMike Inc Blachford Corporation

Eder Engineering GmbH

Hsiang Chuan Machinery Co, Ltd

EJP Maschinen GmbH

IFP Srl Industria Filo Patentato/

Elantas GmbH

Ideal-Werk C+ E Jungeblodt GmbH

Emerson CT

Indore Composite (P) Ltd

Ernst Koch GmbH & Co KG

IN-Dun Technology Co, Ltd

Erocarb SA

Inoex Trading (Beijing) Co, Ltd

Esteves China (Shanghai) Diam Dies Co,

Int’l Wire & Machinery Association

Euroalpha Srl

Istituto nazionale Commercio Estero (ICE)

Eurolls S.p.A./Eurolls Group

IVA/Essex SAS.

EuroWire Magazine-Intras Ltd

IWCEA-France

EVG Entwicklungs- und Verwertungs

JC Com Co, Ltd

FIB

Joachim Uhing KG GmbH & Co KG

Fisk Alloy Conductors, Inc

JSC VNIIKP Trade House of VNIIKP

Flymca & Flyro

Kalmark Integrated Systems Ltd

FMS Force Measuring Syst. AG

Kalpena Industries Limited

Fort Wayne Wire Die, Inc

Kappa SteeL GmbH

Friedr. Krollmann GmbH & Co KG

Kato Spring (Shanghai) Co, Ltd Kieselstein GmbH

Bongard Trading GmbH & Co KG

Kolon Industries, Inc

Boockmann GmbH

Koswire Ltd

Borouge Sales & Marketing Ltd Hong Kong

Kunshan San Chi Eng. & Mch Co Ltd

Bühler Würz Kaltwalztechnik GmbH

Kyoeisha Chemical Co, Ltd

Caballé, SA

Kyoudo Engineering Co, Ltd

Candor Sweden A/B/Sweden

Lamnea Bruk AB

Carl Bechem GmbH/Germaty

Lee and Lee Machinery Co Ltd

Ceeco Bartell-Bartell Machinery

Lee Engineering Co, Ltd

CERSA-MCI Srl

Leoni Draht GmbH

Cheng I Machinery Co, Ltd

Lubrizol Adv Mtls Asia Pacific Ltd

China Southern (Group) HK Ltd Clifford Welding Systems Ltd/South Africa Condat Lubrifiants Conductix Wampfler (Delachaux Grp) Conoptica AS Continuus-Properzi SpA Cortinovis Machinery-Eurolls Group CPA Computer Process Auto. GmbH D & S Dies Co, Ltd Dainichiseika (Shanghai) Trading Ltd Danieli Automation SpA Davis-Standard, LLC Deukyoung Co, Ltd Domino China Limited Dongguan Springs Machinery Co Dow Chemical (China) Company Limited DSR Wire Corp Du Pont China Holding Co, Ltd EB Tech Co, Ltd EBNER Industrieofenbau GmbH

46 | WIRE JOURNAL INTERNATIONAL

LUKAS Anlagenbau GmbH FSP-One SAS.

M + E Macchine + Engineering Srl

Fushi International (Dalian) Bimetallic Cable

MAG Maschinen und Apparatebau AG

Gauder & Co SA

Maillefer SA

GCR Eurodraw SpA

Mali GmbH

GH-Electrotermia, SA

Mario Frigerio SpA

Gimax Srl

Maschinenfabrik Niehoff GmbH

Golden Spot Industry Inc

Medek & Schörner GmbH

Gwo Lian Machinery Industry Co Ltd

Micro Products Company

H&R ChemPharm (UK) Ltd

Microdia SA

Hae Dong Industries Co, Ltd

Miltec UV

Haefely Test AG Rep Off Beijing

Miyazaki Machinery Systems Co, Ltd

Hakko Kouyu Co, Ltd

mtt machinery tech trading GmbH

Handuk Ultrasonic Co, Ltd

NBM Niehoff-Bühler GmbH

Hanil Machinery

Nextrom Oy

Hempel Wire Ltd

NHV Corporation Shanghai

Henrich Maschinenfabrik GmbH

Numalliance

HIGHVOLT Prüft. Dresden GmbH

OCN SpA

HMP Heinrich Müller GmbH

Officine Meccaniche di Lesmo SpA

Ho Yin Machinery Co, Ltd

Otomec Srl

Shanghai Southern (Group) Hong Kong Ltd

Unience Co, Ltd

Pengg Austria GmbH

Sheng CHYEAN Enterprise Co, Ltd

Unigel (UK) Ltd

Petrofer Chemie H. R. Fischer GmbH & Co

Sicme Italia Impianti Srl

Unitek Maschinenbau – und Handels GmbH

PH Chem Co, Ltd

Siebe Engineering GmbH

Verband österr. Draht und Kabelmaschinen-

Polyone Corporation

SIKORA AG

Proton Products International Ltd

SIMEC

Vitari SpA

PWT Limited

SKET Verseilmaschinenbau GmbH

WAFIOS AG

QED Wire Lines Inc

Sojitz Machinery Corporation

WAFIOS Umformtechnik GmbH

Queins Machines GmbH

Solvay (Shanghai) Co, Ltd

WCISA – Wire and Cable Industry Suppliers

Reber Systematic GmbH & Co KG

South African Wire Association (SAWA)

Richard Apex Inc.

Southwire

Weber & Scher Mfg Co Inc

Roblon A/S

Spirker Schnellflechter GmbH

Willi Bremer GmbH

Rosendahl Maschinen GmbH

SPX Precision Components

Wire & Cable Technology International

Roteq Machinery

Steuler-bobby (Shanghai) Equipment

Wire & Plastic Machinery Corp

RSD Technik GmbH

Engineering Co, Ltd

Hersteller – VÖDKM,AWCMA

Association

Wire Forming Technology International

Saarstahl AG

Stolberger

WiTechs GmbH

Sandvik Hard Materials

Teijin Aramid Asia Co, Ltd

WKÖ – Wirtschaftskammer

Sansho Shoji Co, Ltd

Teknor Apex Company

Schlatter Industries AG

Totoku Toryo Group

Ya Sih Technology Co, Ltd

SCOB – Silke Schaaf eK

Traxit International GmbH

Zumbach Electronic (Shanghai) Co, Ltd

Shanghai Hamana Machinery Co Ltd

Troester GmbH & Co KG

Österreich

AUGUST 2012 | 47

EVENT PREVIEW

Pan-Pioneer Co, Ltd

FEATURE

Power Cables B

y one report, the global power cable market, valued at $98 billion in 2010, will reach $150 billion in 2015. HV and EHV is a tiny slice of that market, but this feature focuses on it due to impressive investment in the U.S. and a sense of activity to come.

In a way, you can say that this is the best of times for manufacturers of high-voltage (HV) and extra-high voltage (EHV) power cables. In the last few years, ABB, LS Cable & System, Nexans and Prysmian have all either announced or begun to carry out ambitious plans for plants to manufacture EHV cable in the U.S., which previously had no such production.

Global energy demand is already a strain to meet, and it is projected to increase as much as 30% by 2040. There is a greater focus on providing more energy from renewable resources such as solar, wind and hydropower. Only, in the U.S. that is not so easy as its power gridâ&#x20AC;&#x201D;which serves more than 143 million customers through more than six million miles of transmission and distribution

This Integer Research charts reflects the logistical challenges for energy generation in the U.S. 48 | WIRE JOURNAL INTERNATIONAL

“Some have argued that the best solution to this suite of problems is to construct a nationwide overlay or ‘super-highway’ grid. Others favor large, discrete transmission projects that connect sizeable renewable resources to major load centers. Still others defend a more conventional buildup of transmission reinforcements—within regions and across multiple regional boundaries—and more use of local renewable resources.”

The report authors say that the multiple and challenges pose considerable obstacles to resolving the problems as many different interests must be taken into account.

“We do not recommend or oppose any particular suite of investments. Given the complexity of transmission expansion and the many competing alternatives, this is a matter for careful decision-making by knowledgeable stakeholders. Only by unlikely coincidence will the public interest be served by transmission plans dictated by legislation or based on comprehensive visions devised from afar.”

The bottom line, however, seems to be that, whatever method or methods are supported, however the Smart Grid develops or whether cable is to be overhead or buried, a lot of power cable business will exist for cable makers.

Report: submarine cable niche is growing by offshore wind projects

nection will place on the market. The constraints on the supply chain don’t stop with the manufacturers. The site engineering companies and cable-laying ships required are also highly specialized and also in limited supply.”

Europe will continue to be the leading region for submarine electricity cable deployments, representing nearly three-quarters of all projects by 2020, the release said.

Asia Pacific, it added, will be the next largest regional market, followed by North America.

The report predicts that the deployment of high-voltage direct current (HVDC) projects will outpace high-voltage alternating current (HVAC) cables in the coming years.

While the first undersea cables deployed were HVDC, many of the deployments through the 1990s and 2000s used HVAC for ease of integration into the power grids, making the technology cheaper to deploy, it said. But recent advancements in HVDC cables and equipment, it noted, “have brought on a rash of new HVDC cable installations, and these systems can also address projects that handle longer distances, higher voltages and deeper routes than HVAC.” For more information on the report, which examines the market opportunity and demand dynamics for HVDC and HVAC submarine power cable projects around the world, contact Pike Research at tel. 303-997-7609, www.pikeresearch.com.

“Submarine Electricity Transmission,” a report on the high-voltage submarine transmission market from U.S.based Pike Research, finds that this niche—that once had few purchasers and even fewer suppliers—has seen its market expand beyond its traditional role, resulting in “good news-bad news” for the sector.

The press release from the “cleantech market intelligence firm” said that the high-voltage submarine transmission cable market was largely slotted for connecting islands to nearby national grids. That has changed in recent years due to the need for grid interconnections and connecting offshore wind farms to nearby landmasses, it said, noting that Pike Research predicts that submarine transmission cable projects will increase from just over 60 worldwide in 2011 to more than 350 by 2020.

That growth, the release said, will place significant pressure on the existing industry supply chain. “Only a handful of manufacturers in the world are capable of producing and installing high-voltage subsea power cables,” said Pike Research President Clint Wheelock.

“Our analysis indicates that the limited supply chain for cables is not prepared to meet the increased demand that offshore renewable energy production and grid intercon-

AUGUST 2012 | 49

FEATURE

lines—is not set up in a way that makes it practical to locate power generation sites. The chart on the preceding page shows the most appropriate places to locate generation sites for wind and solar power.

The Future of the Electric Grid, an interdisciplinary multi-part study by MIT, extensively covers the subject (http://web.mit.edu/mitei/research/studies/the-electricgrid-2011.shtml). Its scope includes the continental U.S., which has three independently synchronized grids: the Eastern Inter connection, the Western Interconnection, and the Electric Reliability Council of Texas (ERCOT), which are linked by only a few low-capacity direct current lines.

For the best onshore wind and solar resources to be tapped efficiently, an increasing fraction of transmission lines will have to cross state borders, independent system operator (ISO) regions, and land managed by federal agencies such as the U.S. Forest Service, the report said.

“There is too little useful transmission planning at regional, interregional, or interconnection wide levels; the costs of boundary-crossing projects can be allocated only through project specific negotiations; and the need to obtain construction permits from multiple authorities makes it difficult to site and build boundary crossing lines.

Nexans further commits to power cable with its new plant in the U.S. Nexans recently broke ground on its first high voltage cable manufacturing plant in North America. Its new plant in Berkeley County, near Charleston, South Carolina, will reinforce the company’s position in the fast growing HV cable market as well as extend its presence in North America. The $85 million investment is for transmission lines for underground use in urban areas, with future products to include underwater power cables.

“The establishment of our first high-voltage cable manufacturing plant in North America is a key strategic development for Nexans. It will enable us to capitalize on the ever growing demand for high-quality high-voltage cables designed and manufactured to meet the specific needs of the major power transmission infrastructure projects planned in North America and worldwide in the coming years,” said Fréderic Michelland, Nexans Senior Corporate Executive Vice President, responsible for the global high-voltage and submarine cables business as well as activity in North and South America.

Below, Cam Dowlat, vice president and general manager for Nexans’ U.S. Business Group, briefly discusses the technology, competition and more.

WJI: Nexans is making quite an investment here: is the company convinced that demand for HV cables not only exists, but that there is also the willingness by customers to pay for it?

Dowlat: High Voltage XLPE (solid dielectric) underground cables have been installed in North America for over 25 years. Today over 90% of HV underground cables are XLPE, replacing the fluid-filled types that were predominantly used in North America. In the last 20 years, the large majority of HV cables have been imported. There is a substantial market for these highly engineered products, ranging from 69 kV to 500 kV, and it makes sense to manufacture locally. Underground cables are installed in urban areas and in many cases where overhead lines cannot be used, or are difficult to get permitted. There are many transmission projects planned in the U.S. and Canada over the next 20 years. Where it is practical overhead cables will be used, but in many projects, underground cables will be employed, because of right-of-way issues, urban development, aesthetics, and permitting.

WJI: Can existing/planned U.S.-based competition from ABB, Prysmian and Superior Essex/LS Cable significantly impact potential orders/margins? Is there enough business for everyone?

Dowlat: It is a very competitive industry, with domestic and overseas cable suppliers. We believe that local suppliers that have a good track record, meet all the customer requirements and industry standards, and are at the leading edge of the industry, have a competitive advantage.

50 | WIRE JOURNAL INTERNATIONAL

WJI: How many other EHV plants do you have, and will the technology used here be essentially the same as those? How extensive is training for employees? Will that be handled by your equipment supplier or also from your staff that is experienced in this area?

Dowlat: Nexans has several EHV plants in Belgium, Germany, Norway and Japan. The products and manufacturing processes used here will be a transfer of technology of our existing technology, and in line with the international standards such as those of the Association of Edison Illuminating Companies (AEIC) and the International Electrotechnical Commission (IEC).

Nexans pays particular attention to training. Engineers and technicians and operators will undergo extensive training in our existing manufacturing facilities before the start of operations in South Carolina, including training according to the Nexans Excellence Way (NEW).

Cam Dowlat, vice president and general manager for Nexans’ U.S. Business Group WJI: How much more demanding is the EHV process in terms of achieving the required product quality?

Dowlat: EHV products for our facility in South Carolina will undergo extensive qualification and type testing according to standards IEC and AEIC. The qualifications are carried out by internationally recognized test facilities, and include electrical, material, mechanical and physical testing. We have material suppliers who specialize in supply of polymer and other materials for high voltage cable manufacturing.

WJI: Will plant production be dedicated for the U.S.?

What percentage of production will be EHV? Dowlat: The plant will be primarily to supply North American clients. We anticipate also to serve our clients in South America. We will, of course, have North American clients such as the Engineering, Procurement and Construction companies (EPC) who will have overseas projects.

Below are short takes on a new power cable and a sharpened focus on an overall approach to power needs.

• LS Cable & System. The company recently introduced what it describes as the first fireproof cable for offshore structures and ships that is capable of withstanding temperatures up to 950°C for two hours. The cable has “the highest temperature resistance ability of any cable in the world,” a press release said. It noted that general fireproof cables are rated to 750°C while the LS cable is effective 200°C higher. It said that was possible by adding glass fiber and improving the properties of the mica used in the fireproof tape. The company notes that the cable also operates normally against external impacts and watering that typically occur during a fire-ighting situation.

• The Prysmian Group. One of the latest announcements from the Prysmian Group reflects the need for cable manufacturers to proceed with a thorough understanding and product deployment meant for the “Smart Grid.” To that end, the company has introduced “high-tech solutions and products for utilities and grid operators.”

“Prysmian Group’s products and solutions are divided into four different areas, depending on the solution proposed: risk prevention, smart maintenance, electrical load management and environmental impact,” a press release said. “Solutions have been identified and developed for each area that can be applied to existing grids as well as integrated in future ones.”

“In coming years we will see a radical change in the way that the global electricity system works, offering many benefits to all users in terms of efficiency, quality and security of supply,” said Prysmian Group Power Distribution Business Director Massimo Comina. “This is why it is necessary to go beyond the traditional cable concept and provide innovative solutions that satisfy the new grid requirements in terms of renewable energy, energy efficiency and lower environmental impact,” he said.

Though Micro-Weld electric resistance butt welders were born over 80 years ago in the U.S.A., today our value-added welding solutions help customers in over 30 countries. Tough, accurate, dependable butt welders, and unmatched service and support worldwide. Micro-Weld. The ideal choice for continuous processing of wire, rod and cable. Find out more by calling Booth No. W1G14 Shanghai China 1-800-872-1068, or visit www.micro-weld.com September 25-28

Micro Products Co. • 1886 E. Fabyan Parkway • Batavia, IL 60510 U.S.A. Phone: 630-406-9550 • Fax: 630-406-9552 • Email: info@micro-weld.com

AUGUST 2012 | 51

FEATURE

A ‘hot’ cable design and a ‘smart’ approach to the overall package

FEATURE

Southwire: overdue investment in the U.S. power grid has begun A key U.S. supplier of transmission and distribution products, Southwire Company was chosen earlier this year to supply the overhead transmission cable for the Rock Island CleanLine, a project that will require approximately 500 miles of overhead, high voltage direct current (HVDC) transmission line that will deliver 3,500 megawatts (MW) of renewable power from Iowa, Minnesota, Nebraska and South Dakota to communities and businesses in Illinois and other states to the east. That project epitomizes the potential for power cable. Below, Carol Godfrey, vice president of marketing and product development for energy products for Southwire Company, discusses the sector.

WJI: Do you believe that the U.S. has finally entered into a period where substantial investment is being made to its power grid? Is this a long-overdue step?

Godfrey: While the debate continues over the relative size of the required investment in the North American power grid, the drivers that have resulted in increases in spending are well entrenched for the next five plus years.

So the long-overdue spending has in fact already begun as the grid now needs to: transport renewable power from remote generating areas to population centers; relieve congestion points along the grid that constrict the flow of cheaper energy resources; and replace, upgrade and harden transmission assets that have been in place for over 60 years. Add that to the overall need for the gird to become more “smart,” through initiatives underway for the SmartGrid, and you have a renewed focus and investment in what is not in fact a single grid, but the compilation of several transmission grids across North America.

WJI: There are headlines of numerous projects, some quite large, such as the above cited Clean Line project.

Should these projects be seen as signs of progress in terms of the overall grid needs?

Godfrey: Very much so. Projects of varying scale— from short reconductoring projects along existing rightof-way to large long-haul transmission projects—are working their way through the complex process of planning, citing and construction. Specific geographical areas, such as Texas and California, are already well underway with their transmission activities as a result of near-term wind and solar generation requirements. These projects tend to be longer in distance and higher in voltage. The multi-state and multi-province nature of some of the long line projects finds utilities forming joint ventures as the regulatory process can be state specific. And companies such as CleanLine are working toward HVDC lines that will provide point-to-point delivery of bulk amounts of power from remote areas (think about wind in Iowa) to areas of need (think Chicago or the PJM area of the grid).

52 | WIRE JOURNAL INTERNATIONAL

WJI: Regarding your project for Clean Line, was DC chosen over AC because of the length of this specific line, and if so, was there a specific point (distance-wise) that would have made an AC line the better choice? Was the need for the cable to connect to the PJM system also part of the reason for the DC choice?

Godfrey: HVDC projects such as the CleanLine projects and those proposed by AEP and other transmission owner/operators are quite specific in terms of their purpose and their design. DC becomes a very viable design option when large quantities of power need to be moved Carole Godfrey, vice president efficiently across hunof sales and marketing for dreds of miles, from point A to point B. I sort energy products for Southwire Company. of like to think HVDC as a highway that travels, say, 500 miles, with only one entrance ramp and one exit ramp. So, if you need that highly efficient transport of a singular set of goods, then HVDC could deliver wind power to the PJM system.

WJI: Your website cites some of your company’s technology advances for power cables (3M™ Aluminum Conductor Composite Reinforced (3M ACCR) high voltage overhead conductor/Ultra High Strength Core HS285®/VR2® cables: were these prompted by requests (or perceived demand) from power company customers?

How closely do you work with customers in developing such advances? Are you working on others you hope to introduce soon?

Godfrey: I’m glad you asked about product innovation.

As the North American grid becomes more complex and more taxed, let’s remember that much of this network was designed and constructed decades ago, Southwire’s customers are challenged to better use their existing infrastructure. That often means reconductoring exiting lines to get more capacity down the line. So, yes, we have worked to develop products like our high-capacity HS285. But in other cases, environmental stresses such as wind and ice are just a regular part of the operations. Yet excessive wind and ice can result in downed lines so customers want products like our vibration-resistant VR2.

Customers continue to present us with problems that are ripe for innovation. Most recently, our product development team introduced Southwire Proof Positive Copper to help curb copper theft in utility substations, and I’m thrilled that the development funnel is full of projects.

WJI: Most discussions about transmission, at some point, divert to an overhead transmission versus underground transmission discussion. Any insight that you might want to throw in to the debate?

Godfrey: Interesting that you would use the word debate, since the issue can be polarizing. We don’t see it as an all-or-none discussion. Advances in underground transmission cables, accessories and installation methods have expanded the voltages for such applications as well as increased reliability and brought down costs, no doubt.

Yet, overhead lines are quite cost effective and reliable and are the enabler for the vast expanses of geography that must be covered. There are plenty of opportunities for both overhead and underground to be deployed and often deployed on the same line.

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WJI: Is it fair to say that power cable capability and availability is not the issue so much as it is planning/consensus on how and where the power grids should be upgraded? For instance, how can a potential generator of renewable energy be confident that if they locate on a site that may be ideal for their purposes, that they will be able to connect to a grid capable of transmitting power?

Godfrey: Your point about generators seeking certainty regarding access to transmission and on the flip side transmission regulators and operators looking for clarity about loading and power demand is what might be called a transmission/renewables “poultry issue”: the chicken or the egg. Texas began working on their poul- Overhead power cable supplied by try issue sever- Southwire Company. The company offers al years back power cable for either above-ground use by establishing or for burial. a requirement that the Texas grid be expanded such that 10,000 Megawatts of renewable generation could be accommodated. The result: a series of projects referred to as Competitive Renewable Energy Zones (CREZ).

FEATURE

The higher the voltage, the more demanding the specs for materials Two global leaders in supplying essential materials for power cables are Dow and Borealis AG. Below, Robert Tarimo, global segment leader, HV/EHV, Dow Electrical & Telecommunications (Dow E&T), The Dow Chemical Company, and Anton Wolfsberger, marketing manager, wire & cable, Borealis, discuss their field.

WJI: How much more demanding are the requirements for the raw materials for production of EHV and HV cables?

Tarimo: Higher voltage compounds are used in critical cables on power transmission networks across the globe. The quality of insulation system materials is vital in ensuring the longevity, reliability and efficiency of these networks.

Ensuring quality compounds requires substantial investments Robert Tarimo, global segment and continuous leader, HV/EHV, Dow Electrical & improvements over many years Telecommunications. At wire 2012, and therefore the he spoke in favor of setting industry industry demands standards that are higher than the minimum requirements of different few strategic, global mandates. committed, reliable and knowledgeable suppliers. Dow E&T has that track record and long term commitment to the industry.

Wolfsberger: Borealis and Borouge are recognized throughout the wire and cable industry as trendsetters for innovation in technology and products. With more than 45 years of experience, we are the reliable partners of choice in offering high quality polyolefins for a wide variety of power transmission and distribution cables as well as electrical and fiber optic communication applications.

A thorough understanding of the requirements of the value chain and EHV/HV cable manufacturers is needed to produce materials for EHV and HV cables. To produce a compound for an HV and certainly for an EHV cable, a high level of know-how and experience is required. Most importantly is the hardware and software used to produce these unique polymers. This starts with the proper compe54 | WIRE JOURNAL INTERNATIONAL

tence, quality and zero-failure mindset of the employees to produce compounds for EHV cables. EHV compounds can only be produced in a dedicated plant with a closed loop from the monomer to the final packaging and especially by people who are thoroughly trained.

The market for EHV cables (1%) is relatively small compared to the total wire and cable market and the investment level needed to produce compounds for the EHV market is relatively high. Additionally the need for super-clean materials has increased over the years, and only very limited players were able to follow this evolution by continuous technology evolution and advances.

Therefore, very few compound producers can afford and are capable of producing HV—and especially EHV— compounds.

WJI: How small a contaminant can cause a problem in an HV or EHV cable? What special measures go into making sure this does not happen on your end?

Wolfsberger: If a small box of matches filled with small contaminations above 100 microns was distributed equally over the entire production throughout one year, it would force a downgrade of the entire production of HV compounds to a lower quality level. If a teaspoon was filled with contaminants (more than 70 microns) and spread over our EHV production from one year, we would contaminate the whole production for a one full year.

Making EHV and HV compounds is a constant struggle for us to ensure we do everything possible to prevent contaminants. The whole process is set up to make it as smooth as possible without any interruptions so that we have a very consistent and constant quality throughout the year. This also helps us to minimize the variations between the different batches. To achieve our goals. we have introduced significant technological advances and established the highest quality and purity standards.

Tarimo: We are talking microns when discussing how small of a contaminant can cause a problem in an HV or EHV cable. Contaminants can cause breaks in insulation or protrusions in the smoothness of the outer jacket of the cable, both potentially leading to power losses or cable failure.

At Dow E&T we have set up many special measures to ensure a super-clean end product. There are quality systems in place throughout the resin intake, compounding and extrusion processes to ensure that finished pellets are contaminant-free. Packaging takes place in a clean-room environment and compounds are then stored in temperature-controlled warehousing until ready for transfer to our cable manufacturer customers. With all these measures in place, the intent is to control variability—keeping it to an absolute minimum from one batch to the next—ensuring that all finished compounds meet strict industry standards.

Furthermore, we have packaging systems that ensure our customers can unload our materials in a clean manner at their site.

Anton Wolfsberger, marketing manager, wire & cable, Borealis, at wire 2012.

WJI: To what degree does your company partner with its customer versus supplying them? What is the difference?

Wolfsberger: If you are in the EHV business, you cannot do it on your own. There is a constant dialogue with

our customers to make sure we are able to meet their increasing demands. We have been able to produce compounds from 161 kV up to 400 kV and now up to 525 kV all based on requests from our customers. Both the cable producer and compound manufacturer are helping each other to extend the limit of what is possible with a crosslinked polyethylene (XLPE) compound.

By successfully applying our well-known proprietary BorstarÂŽ and new Borlink technologies, we have delivered a step change innovation for the plastics industry.

Moreover, in 2010, Borealis completed a major investment of nearly 400 million euros at its plant in Stenungsund, Sweden, to enhance its capability to provide advanced Borlink materials for the entire wire and cable market. Additionally, at the end of their useful life these cables can be fully recycled in combination with standard PE for a fully sustainable multi-generation life cycle. Applying these technologies enable us to deliver a wide range of material solutions, such as our unique Supercureâ&#x201E;˘ XLPE for high productivity, as well as the first globally available solutions for HVDC cable applications. Our commitment to the industry is clearly demonstrated by our continued investment in resources and capacity, linking all areas of the wire and cable world and bringing energy all around.

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Tarimo: Dow E&T is committed to setting industry standards that are even higher than the minimum requirements that are globally mandated. We look to work with customers that are as committed as we are to achieving those standards in finished cables produced with our materials. That is the impetus behind our Dow Inside program, where we partner with cable manufacturers to ensure that our quality materials combined with their

A Dow employee in a “clean room.” quality manufacturing processes produce a superior cable that will provide reliable, long-life service to the end user and lower total cost over the lifetime of the system in which the cable is installed. Obviously, this requires a great deal of collaboration and trust rather than simply providing a raw material to produce an end product. We work with our customers every step of the way, from upfront in-house testing and validation of our materials to helping set up the best processing parameters for our products using their equipment. We also cooperatively market to end users, stressing the message of quality materials plus quality manufacturing that exceeds industry standards is the optimum way to achieve a reliable, long-life power transmission and distribution system.

WJI: To what degree does your company partner with its customer versus supplying them?

Tarimo: The manufacture of quality HV and EHV cables relies on the expertise and close collaboration between the cable manufacturer and the compound supplier. The “clean chain” from polymer production to compound manufacturing, compound transportation and cable manufacturing needs to be managed by both partners effectively to avoid contaminants entering the system at any stage. Therefore, you can imagine that a great deal of consideration has to be made for the logistics of planned capacity, manufacturing, packaging, storing and shipping all to manage just-in-time and quality requirements for the cable manufacturer. Dow E&T recognizes the impor-

56 | WIRE JOURNAL INTERNATIONAL

tance of this collaboration and has introduced programs like Dow Inside to enhance this collaboration to deliver quality and timely cables.

Wolfsberger: Most EHV cables are sold on a project basis. This means that the cable producers quotes for an EHV project and has to be sure that if he wins the project he will be able to deliver within the requested time frame.

Therefore it is vital that the cable producer can count on Borealis to have the EHV compound available when he needs it. We produce EHV compounds on a continuous basis to make sure we have enough material available when an EHV project is to be delivered. It is not only very important for cable producers but also the value chain to rely on proven technology and long-term records as any failure in underground cables would lead to significant financial and image damages.

To support the importance of delivering reliable and steady material for EHV and HV cables to the wire and cable industry, we launched a new technology brand at wire Düsseldorf, Borlink™, that will set the pace in the wire and cable power industry in the years to come on a global basis.

Key innovations of Borlink include a tailor-made high pressure (HP) process for the production of high purity and super clean low density polyethylene (LDPE) base polymers with superior electrical properties and the introduction of a closed or controlled loop (from monomer to final packaging) which avoids contamination and ensures homogenous and high quality clean compounds. Borlink is a wire and cable industry-wide platform cross-linking the technology, products and expertise to connect networks and grids as well as people and their access to energy. The establishment of Borlink represents another step change innovation specifically for the wire and cable power industry. It underlines Borealis and Borouge’s commitment to the industry as it provides an outstanding resource to help meet the challenges the industry faces in the future. With Borlink, Borealis and Borouge have elevated their total network of support to a new level by helping to facilitate the linking of different grids and energy sources together both regionally and globally.

FEATURE Projected life costs per km for a 75 km route for different power cables. Chart by Parsons Brinckerhoff and Associates.

Life cycle tells story on actual costs for different types of power cable Electricity Transmission Costing Study, a 355-page report prepared and issued earlier this year by U.K.-based Parsons Brinckerhoff and Associates for the Institution of Engineering and Technology issued a list of findings about costs for different methods of transmitting electricity. Below are some of the findings. The full report can be found at http://web.mit.edu/mitei/research/studies/the-electric-grid-2011.shtml.

• Costs per km, for all technologies, tend to fall with increasing route length.

• Costs per km, for all technologies, tend to rise with circuit capacity.

• All technologies emit losses, and these vary significantly with route length, with circuit capacity, with circuit loading and with transmission technology.

• For options using a deep tunnel, the largest single cost invariably is the tunnel itself, with costs from £12.9m to £23.9m a km, depending on overall tunnel length.

• Overhead line (OHL) is the cheapest transmission technology for any given route length or circuit capacity: lifetime cost between £2.2m and £4.2m per km.

• Underground cable (UGC), direct buried, is the next cheapest technology for any given route length or circuit

capacity. It also represents the least expensive underground technology, with the lifetime cost estimates varying between £10.2m and £24.1m per km.

• High voltage direct current (HVDC) exhibits the highest proportion of losses of any of the technologies (see figure).

The losses principally occur at the converter stations at the ends of the connection, and much longer HVDC connections would be more efficient and have lower costs per km.

• HVDC current source converter (CSC) technology is e the cheaper HVDC option per kilometre over 75 km (ranging between £13.4m and £21.9m a km), depending upon converter capacity), and these unit rates would drop as the length of the connection increased.

• HVDC voltage source converter (VSC) technology is the most expensive option over 75 km, between £16.4m and £31.8m a km. As the VSC technology can offer distinct and unique advantages to the wider transmission system, in some circumstances this cost may be offset in other ways.

• HVDC converter technology is developing quickly and costs could fall further as newer and larger HVDC bipole designs are employed in the U.K. • Gas insulated line (GIL) technology is generally higher in cost (between £13.1m and £16.2m per km) than the lowest rating (Lo) underground cable studied (£10.6m to £12.8m per km), although the GIL equipment does have a somewhat higher rating than the compared UGC. AUGUST 2012 | 57

EHV extrusion technology: a place where few OEMs compete FEATURE

Two premiere suppliers of HV and EHV extrusion technology are Germany’s Troester GmbH and Switzerlands’s Maillefer SA. Dirk Schmidt, sales director for Troester’s Cable Machinery Division and Juha Hiltunen, director of sales and marketing for wire and cable for Maillefer, shared their thoughts about the field with WJI. WJI: Why are there so few suppliers of EHV equipment?

Hiltunen: Production of EHV/HV cables is very challenging in terms of value of the cable, not to mention the direct and indirect cost of damage to the installed cable.

Very few equipment providers are willing to take the risks of providing complete manufacturing systems which ensure production of premium energy cable. Maillefer has accumulated its know-how and experience during nearly 40 years. The development efforts and continued improvements have kept Maillefer a technology leader throughout.

Schmidt: In the production of HV and EHV cables high material costs are involved and failures mean scrap and high losses. Reliable technology with long continuous production runs at constant high product quality is required. The cable producers rely on proven equipment.

The excellent results produced by our extrusion technology made Troester a market leader for CV Lines for MV, HV and EHV cable production.

Dirk Schmidt, r, sales director, cable machinery division, Troester GmbH, with Michael Neubauer, president and CEO, Troester Machinery Ltd., at wire 2012.

WJI: EHV cables have to meet very demanding specs: how difficult is it for employees to be trained in the use of your equipment? How foolproof is your equipment?

Schmidt: Foolproof would be nice, but on the manufacturer’s side certain skills and expertise are required to produce high quality HV and EHV cables. Normally our

58 | WIRE JOURNAL INTERNATIONAL

WJI: To what degree is the equipment only part of the equation: just how important is the level of service and support you can offer customers?

Hiltunen: Know-how is a very important part of the package. Maillefer is able to help customers master not just the extrusion processes, but the whole HV/EHV production chain.

Troester: We see the relation with our customers as a long-term partnership which goes on after the sales of the machine. Service is essential part of the entire package.

Juha Hiltunen, director of sales and marketing for wire and cable for Maillefer SA, at wire 2012.

WJI: Are there any notable trends in EHV and HV production (from EHV size to ensuring material purity) that your company has made adjustments for in recent years?

Schmidt: The task of material purity is basically the target of the material suppliers who offer the material in different grades and cleanliness levels. The responsibility of Troester is to take care that this high level of cleanliness will be maintained until the material is processed in the extruder and possible contamination is avoided.

Hiltunen: Maillefer has developed a long run concept to serve HV/EHV production, especially for the submarine cable production, where long-length delivery is a must. In addition, continuous improvements that increase equipment availability, performance and quality (i.e. overall equipment effectiveness) are kept a top priority in our development work.

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FEATURE

customers are already active in cable production before starting with HV and EHV, thus the basics are already there. The special skills required for HV and EHV cable production certainly are transferred to our customers during trainings.

Hiltunen: The process itself is very highly automated.

Training is needed to understand the key parameters of the process and to concentrate on the most important factors such as avoiding the scrap and optimizing productivity.

FEATURE

The test is the focus for HV/EHV For a myriad of reasons, testing of power cables is vital because of the sector’s role and potential harm from failures. One company that specializes in equipment for HV testing is HIGHVOLT Prüftechnik Dresden GmbH, which also furnishes research and educational institutions with its systems and equipment. Below, Sales Director Dr. Ralf Bergmann discusses the field.

WJI: What are the most crucial testing aspects for HV power cables and why?

Dr. Bergmann: It is important to find any small defects in the insulation that cause partial discharges and finally breakdown during the operation of the cable. However, testing should not damage the “healthy” insulation.

Cables are therefore tested in the factory with prequalification tests that prove that a manufacturer in general is able to design and produce cables that prove to be reliable in service, type tests proving the design of a specific cable type, and routine tests, which are AC withstand tests combined with PD measurement that mainly aim on material and workmanship, and find small defects in the insulation. On site after-laying tests are intended to cover not only the cable itself as in the factory, but the complete cable system including accessories. As the cable itself has already been tested in the factory the main focus is on damages during transportation and laying, and the terminations and joints assembled on site, which may also contain defects due to workmanship, material and imperfect conditions on site. Finally, testing for diagnostic purposes allows a utility to detect insulation defects early and fix them during scheduled maintenance instead of facing unpredicted outages.

WJI: How reliable are your tests? Just how small a defect can your equipment discover?

Dr. Bergmann: Cables, especially the new XLPE cable, are one of the most reliable components of the power system. This is mainly caused by a rather simple design for instance in comparison to transformers. The manufacturing process is highly automated. The manufacturing quality is monitored by several measures. At the end each cable will be tested with high voltage and partial discharges are measured. By such measurements even the smallest defects can be recognized before the cable leaves the factory. HIGHVOLT provides the necessary HV test equipment and partial discharge (PD) measuring system.

Due to the high sensitivity of the PD measurement the test takes place in a shielded room which will also be provided by us. If the cable passes such a test it is supposed to have a very long lifetime of many decades.

As a cable can be damaged during transportation, laying and jointing after-laying tests are a must to ensure a long lasting and safe operation. Due to its huge size it is usually not possible to use the same equipment on-site as in the factory. Consequently, special test systems for on-site testing have been developed.

60 | WIRE JOURNAL INTERNATIONAL

HIGHVOLT Prüftechnik Dresden GmbH Sales Director Dr. Ralf Bergmann at wire 2012.

For oil-paper cables the DC withstand voltage test works very well, but for XLPE cables any DC stress leads to the accumulation of space charges in the cable and especially its accessories. After the cable will be energized with AC the polarity reversal leads to greatly increased electric field strengths in the area where space charges are located. This creates partial discharges and new insulation defects, which can lead to subsequent breakdown of a formerly healthy cable.

In 1995, HIGHVOLT developed a compact mobile test system working in the frequency range of 20 to 300 Hz to test HV and EHV XLPE cables. Working in this frequency range, the measuring results are comparable to 50/60 Hz stress under normal operating conditions. Many thousands of tests have been performed with this test method.

WJI: What are the most common faults that tend to happen to active power cables over time? Are those faults problems that could have been avoided by better testing or are they related to inherent problems that can take place over years of service?

Dr. Bergmann: In 2009, CIGRE Working Group B1.10 published “Update of service experience of HV underground and submarine cable systems,” covering 33,000 km of underground land cables and 7,000 km of submarine cables. This investigation of 855 service failures hap-

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tested with DC. Because of the physics, AC test systems are usually much bigger than DC test systems. Also, AC cables need more test power than DC cables. For the new XPLE DC cables the discussion is still going on (for instance, CIGRE WG 21.01) as to which test procedures are best.

One might think that a DC test on a DC cable would be sufficient, but existing weak spots can be much better detected using continuous AC testing as they will cause PD at AC voltages and can be usually found much easier.

The principle is similar for both AC and DC as the electrical behavior is much the same for both cable types when tested with AC voltages. The only difference is that DC cables are usually used for longer lengths and AC test frequencies will go down to 10 Hz. We offer test systems for both types for testing in the factory and on-site.

WJI: We have heard of several test systems set up in parallel for testing very long cables. How does that work?

Dr. Bergmann: For MV cables the equipment is always quite small, due to the low test voltages, usually moderate cable lengths and therefore low test currents.

But for HV and EHV cables the voltage, length and current usually increases dramatically. We have decided to fit our equipment on standard trailers which can easily be brought on site without requiring a special transport permission. So for large cables more than one system can be set up in parallel and/or series configuration. This also provides more flexibility. There are more than a hundred systems around, so a utility might get one system for their own for testing most of their cables, while renting additional systems in case a very large cable is due.

AUGUST 2012 | 63

FEATURE

pened between 2002 and 2005 came up with interesting results.

For instance, failures of paper-insulated, lead-covered (PILC) cables happened mainly at the end of the service life, caused by its natural aging. Internal failures and faults caused by external impact have approximately the same share. 60% of failures happened at the lower voltage classes and 34% of all faults were caused by third-party mechanical defects. The report said that “internal failure rates of accessories, particularly on XPLE cables, are of higher and greater concern. Focus on quality control during joints operations must be maintained.”

The investigations show that the A unique parallel HIGHVOLT setup that connected two mobile on-site test systems to natural degradation of the insulatest an extra long HV cable. Photo courtesy Canada’s Kinectrics Inc. tion and small defects still have a major impact on cable lifetime. HV tests in the factory and after instalWJI: Is it any more difficult to test a continuous cable lation, in combination with PD measurement, are increasthat can be many km long? ingly important to ensure the quality of the cable to find Dr. Bergmann: In a normal test setup, the test current even small failures before the cable is energized. Failures flows through the inner conductor and has to return can be very costly because the repair time of DC submathrough the outer shield. When the cables get very long, rine cables takes approximately 60 days. It is important such as for submarine cables, the test current is in the not only to test but to perform the right tests. The test order of some 100 A, and becomes too large when one voltage should represent the stress that occurs during would test at 50/60 Hz as the cable would start to heat up normal operation. For instance, AC cables should be beyond its specification. This can be avoided by several stressed with AC. Other test voltages with small frequenmeasures for which our test systems are prepared, such as cy, DC charging and very few oscillation does not seem the reduction of test frequency down to, for example, 20 to be the best way to ensure the quality of these important Hz, using test current supply from both ends of the cable. cables.

These two measures allow testing six-fold length compared to a 60 Hz test. HIGHVOLT has such innovative WJI: Is testing more difficult for AC or DC HV lines? test methods already on the market and they will be used Dr. Bergmann: Normally during routing and on-site by leading manufacturers of submarine cables. testing, an AC cable is tested with AC and a DC cable is

TECHNICAL PAPER Zero and beyond: General Cable’s vision for safety A four-part approach to safety has been found to benefit both employees and the company in terms of morale, workforce stability and reducing workers comp costs.

By Tim Wampler

General Cable has one worldwide safety vision: Zero and Beyond. Zero accidents in the workplace, and the expectation that associates will take our safety culture Beyond our facilities and into their personal lives and communities.

Nothing else is acceptable! At General Cable, we feel we have a moral obligation to achieve Zero and Beyond, and thus we have focused on building a structure to accomplish this responsibility. This structure consists of four parts: core beliefs, management systems, elimination/reduction of physical hazards, and safety culture. While the format requires brevity, this paper documents this four-part structure and how it supports the company’s vision.

Core beliefs General Cable’s executive leadership endorsed the vision of Zero and Beyond, an idea that is beautiful in its simplicity and impossible to argue with morally. More detail (applies to all General Cable associates worldwide, includes both safety and environmental concerns, related to both injuries and illness) is used to clarify this vision in the Company’s Corporate Health and Safety Policy. While every company should take the time to draft a Corporate Health and Safety Policy, Zero and Beyond is the statement both our workforce and our leaders rally around.

With a clear vision from the executive leadership, the first step in building the foundation was complete. The next piece of the foundation was to make the vision actionable.

The effort to do so resulted in drafting a Safety Manifesto.

By definition, a manifesto is a public declaration, and every General Cable associate is being asked to sign this document to make public his or her commitment.

Safety Manifesto I firmly believe: • Human life and health have value above all else.

• All accidents are preventable and anything more than zero is unacceptable.

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• Leading safety improvement is everyone’s responsibility.

• I am accountable for my own safety and for the safety of all those around me.

• I have the authority and am personally accountable for stopping any act that is unsafe.

• As a company we cannot achieve sustainable manufacturing excellence without first being world-class with respect to safety.

I will strive to: • Make time to fully understand the safety rules and guidelines of every General Cable facility I enter.

• Lead by example, placing safety first in everything I do.

• Make time every day to reinforce safety expectations and reward safe behaviors.

• Influence others to work safely and thank others for their influence on me.

• Never walk past an unsafe condition or act without addressing it.

• Lead efforts to address known hazards proactively using severity and likelihood as a guide as to where to focus.

• Learn from every incident, every near miss and every benchmark available.

• Take safety beyond the workplace and into my home and the rest of my life.

Some of these statements challenge preconceived notions. For example, the notion that “all accidents are preventable,” causes some people discomfort. The reality is if we do not start with this premise, then we are destined to blame every accident on fate. Blaming an accident on fate ensures that we never put forth the effort needed to get to root cause. However, once people realize that “all accidents are preventable,” they begin to see the underlying risks and foreseeable hazards that created the environment where an injury was inevitable.

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“Leading safety improvement is everyone’s responsibility” and “I am accountable for my own safety and for the safety of all those around me” are fundamental concepts in General Cable’s safety culture. If safety is only the responsibility of management, we will never achieve zero accidents. The necessity of a strong safety culture will be examined in more detail later.

Great plants have great safety records! Experience has taught us this time and time again. Some may argue with the statement, “As a company we cannot achieve sustainable manufacturing excellence without first being world-class with respect to safety,” but there are no In addition to this presentation on safety, General Cable’s Tim Wampler, exceptions to this rule! Safety is a right, was also one of the panelists in the safety roundtable at Interwire 2011. leading indicator of plant performance. Any example to the contrary will be proven false over time. ences1. HFACS was developed by Dr. Scott Shappell and Injuring even a small number of associates leads to poor Dr. Doug Wiegmann, Civil Aviation Medical Institute and morale, low productivity, increased insurance costs, servUniversity of Illinois at Urbana-Champaign. The study was ice misses, etc. It is only logical that injured workers are in response to a trend that showed some form of human not happy workers. Further, injured workers do not make a error was a primary causal factor in 80% of all flight accilot of wire. dents in the Navy and Marine Corps1.

As leaders we know people are more influenced by what The second systemic initiative most companies enter into we do (“never walk past an unsafe condition or act without is an effort at near-miss investigation. In General Cable’s addressing it”) than by what we say (“make time every day case, the same detailed HFACS tools used in accident to reinforce safety expectations and reward safe behavinvestigations are used here. Furthermore, the company iors”). Too often, a daily fire-fighting mentality results in involves hourly associates in every near-miss investigation neither happening. At General Cable, every manager and as well as all accident investigations. To be candid, it is a every associate is challenged to live up to his or her public continuous challenge to drive individuals to report nearcommitment. misses. Fear of embarrassment or the failure to recognize At General Cable, the vision is clear, simple, and moralhow serious the accident could have been results in underly sound, and this vision becomes actionable through the reporting. To get the most out of a near-miss program, words of the manifesto. The foundation is firmly in place. there must be a bountiful use of “carrots” along with a commitment not to use the “stick” when associates raise a Management systems near-miss voluntarily.

Like most companies, General Cable’s safety systems Another common tool is the Safety and Environmental began with accident investigation. Given the sight of a audit. At General Cable, these audits are done using both badly injured employee, the obvious question is what can internal and external auditors to ensure our safety systems be done to prevent that from happening again? However, are compliant with government regulations, but more the real root cause for an accident is often less than obviimportantly to ensure our efforts are leading to an accidentous. Within the company, we use the Human Factors free workplace. Internal corporate audits are not meant to Analysis and Classification System (HFACS), which idenprepare a facility for passing an external audit. Rather the tifies the human causes of an accident and provides a tool intent is to drive action items necessary to improve the 1 to assist in the investigation process . HFACS is based on health, safety and well-being of all our associates.

2 the “Swiss Cheese” model of human error that looks at In addition to corporate and external audits, General four levels of human failure: unsafe acts, preconditions for Cable’s facilities have many different methods of auditing unsafe acts, unsafe supervision and organizational influthemselves locally. It is typical for operators to lead safety

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teams, which are populated principally with other hourly associates. This operator-led structure supports the “leading safety improvement is everyone’s responsibility” statement in the manifesto. There are area audits, where people walk the floors looking for unsafe conditions and 5S audits that are focused on housekeeping and organization. Every facility leader knows that good housekeeping and a good safety record go hand-in-hand.

Furthermore, many facilities have recently begun Standard Work Practice (SWP) audits. SWP audits are done daily in an effort to ensure individuals are following the standard work. The audits are randomly generated so that the person performing the audit, the topic, the timing, and the individual being audited are not predictable on any given day. The SWP audit concept works like this: clarify the expectations in detail. Train the individuals on the topics to be audited. Ensure the audits are frequent enough to reinforce the training and frequent enough that the pool of people being audited are certain their turn for accountability will come. This certainty of accountability and the structure of the program assure disciplinary action is very infrequent. The overwhelming majority of the time auditors are simply praising people for following the documented job safety practices. Each audit becomes an opportunity to emphasize the expectations and the culture through positive affirmation.

Lastly, General Cable utilizes several different safety programs from outside sources to educate employees. For example, the company has trained its workforce on MoveSMART® techniques for years3. MoveSMART teaches practical methods for preventing strains and sprains through techniques for transferring forces away from vulnerable areas of the back, shoulders, neck and knees. How to lift and carry an object is not always intuitive. Training and reinforcement are required.

Elimination/reduction of Physical Hazards General Cable has reduced or eliminated numerous physical hazards in the last year, and while the majority of the company’s improvement ideas come from our hourly associates, data collected from accident investigations indicated the need to focus on hand injuries, specifically cuts to hands. Historically, employees who cut themselves with a knife were likely disciplined, but in hindsight this never addressed the true root cause. Given this perspective, the majority of our plants are now 100% knife-free, which means no open blades can be used in the facility. Other tools have been purchased or developed in order to eliminate the possibility of cutting yourself with a knife. This was no small undertaking, but well worth the effort, given the inevitability of associates cutting themselves when using a knife.

Many of the lathes used in our maintenance shops were decades old. Guarding is now in place to address entanglement concerns. Similarly, many older extrusion take-ups pose the possibility of entanglement. Take-up covers have been developed in some cases and laser curtains have been

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added in others.

Reel handling poses a significant risk of injury in the majority of General Cable’s facilities. Where needed, reel kickers have been added to aid in reducing the physical demands of removing a reel from a take-up. Further, tools have been built or purchased to aid in the movement of a reel throughout the facility. Reel skates and reel-assist bars are typically used for smaller reels. Powered reel movers are required for larger reels.

A recent major initiative was the development of an ergonomic toolkit, which is essentially an internal web portal where information is stored. The toolkit consists of two parts. First, there is a framework that puts the tools into perspective, along with the necessary leadership actions that have been proven to be essential in successful ergonomic programs. Secondly, the toolkit contains detailed tools and instructions that enable those accountable for the ergonomic program to assess risk and then improve their workplaces.

In addition, there are many good safety practices that have been adopted throughout General Cable. One example is ensuring all extruders have pressure safeguards while another is requiring all plant employees to wear steel-toed shoes and safety glasses regardless of how minimal the potential of an accident is perceived.

Although the elimination and reduction of physical hazards is a core part of General Cable’s safety agenda, it is understood that the complete elimination of all risks is not feasible. We will continue to strive to address physical hazards, but this is augmented by the belief that people must consider the consequences of their actions prior to acting.

Safety Culture Human behavior is one of the most difficult variables to address with respect to safety in the workplace. However, in a modern facility it is the most impactful variable in the effort to achieve zero accidents. All risks cannot be eliminated, but associates can reduce the risk to an acceptable level when time is taken to identify and control hazards.

Associates must take ownership for their actions and embrace “Consequence Thinking,” which is when a person chooses the safest way to do a task by identifying and controlling all the hazards feasible, especially their personal behavior so that neither they nor someone around them will get hurt. Consequence Thinking is the only way we will ever be able to reach the goal of zero accidents.

Consequence Thinking takes only a second to do. In fact, it is common for an injured associate during the accident investigation to say, “I was afraid that might happen,” or “the equipment has been like this, I just did not bother to turn in a maintenance request.” General Cable teaches Consequence Thinking not only to encourage people to consider all the relevant risks but also to reinforce that all associates are expected to take action when the risks are obvious.

Other strategies include the requirement of 100% associate participation. Setting the expectation and tracking the results

References 1. L. Musselman and D. White, “The Human Factors Analysis and Classification System (HFACS),” Approach, web, July–Aug. 2004.

2. J. Reason, “Human Error,” Cambridge: Cambridge University Press, 1990, print.

3. MoveSMART is a registered trademark of Strategic Safety Associates, Portland, OR, 97280.

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participation. Setting the expectation and tracking the results ensures some form of meaningful mindshare (leading or participating on a Kaizen event as example) is put forth by all associates. There are also numerous local and global recognition programs. Typically, the award is of minor monetary value, but notable effort is made to communicate the win and praise the individuals for their contributions.

Many of our plants use games like bingo with a safety theme as a way to continually communicate safety expectations in a fun and engaging way. Another common method is the use of Behavior Based Safety (BBS) audits.

Similar to the structure of SWP audits, the intent is to continually underscore expectations through positive reinforcement. While accountability is required when audits are non-conforming, the system is designed in a way that the path of least resistance is to conform. And some General Cable facilities are using hourly associates as auditors. This allows for an exponential number of audits (conversations that reinforce the expectations) to be conducted. However, these facilities do not use any of the work done by these hourly auditors to initiate disciplinary action.

With respect to creating a safety culture where only zero is acceptable, there are two things every employee must adhere to: 1) “Leading safety improvement is everyone’s responsibility,” and 2) “I am accountable for my own safety and for the safety of all those around me.” Practicing Consequence Thinking at work and at home (identify your hazards, understand the risks and manage the risks) before making the wrong decision is the only way to achieve zero accidents.

The results have been noteworthy as General Cable (North America) has seen its OSHA Recordable Incident Rate (ORIR) drop from 2.2 to 1.3 over the last five years.

Further, the reduction in accidents yielded an annual savings of $2 million from lower worker compensation claims. Many manufacturers may consider an ORIR of 1.3 or even 2.2 as an acceptable cost of doing business.

However, given the vision of Zero and Beyond, there is still much to be done.

General Cable considers it a moral obligation to provide a safe workplace for its associates and to encourage them to take our safety culture into their homes and communities. As such, we would welcome the chance to share information about our safety leadership, safety systems, physical hazard elimination efforts and safety culture in even greater detail than this forum provides. Further, we would welcome the opportunity to benchmark the safety efforts of others within our industry as the equipment similarities lead to similar hazards, and left unresolved, similar accidents. Fundamentally, safety is not an area where companies compete. Rather, we all have a moral obligation to our associates and, arguably, to one other to create a safer wire and cable community.

Tim Wampler is vice president of manufacturing, utility, at the Highland Heights, Kentucky, corporate headquarters location of U.S.-based General Cable. He leads and coordinates the activities of six plants that manufacture low- and medium-voltage cables and bare overhead conductor utilized in the transmisWampler sion and distribution of electrical power. He has more than 17 years of wire and cable industry experience. He joined General Cable in 2006 as plant manager of its facility in Lawrenceburg, Kentucky. He previously worked for Belden Wire and Cable, where he held a variety of operations roles of increasing responsibility. He holds a B.S. degree in mechanical engineering from Tennessee Technological University and an MBA degree in operations management from Ball State University. This paper was presented at Interwire 2011, Atlanta, Georgia, USA, May 2011.

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TECHNICAL PAPER Trends and developments in automotive wires Increased environmental and safety requirements combined with the customer preference for full comfort configuration and additional features will be a technological challenge both for OEMs as well as suppliers.

By Dr. Klaus Probst

Global trends will have a major influence on peopleâ&#x20AC;&#x2122;s lives worldwide. Mobility, demographic change, urbanization and environmental awareness are set to play a dominant role and are already having a huge impact on the automotive industry and its suppliers.

Development departments of the OEMs and their partners are working hard on solutions in many different fields. This presentation attempts to provide an insight into the impact of emission reduction, increasing comfort requirements, weight reduction and the miniaturization and electrification of the powertrain in motor vehicles.

Reducing emissions Driven by society, the automotive industry has a clear focus on the development of more ecological drive systems.

In addition to the electrification of the powertrain, improvements to diesel and petrol engines are a major task. The development of engines is mainly driven by the interest of car buyers in low-energy consumption vehicles with good driving performance and the legal regulations from local governments. Huge markets like North America and Europe have very restrictive emission regulations. For example, the current EU standard, EU 5, will be superseded by EU 6, which will set a new emission level, by September 2014 for passenger cars and light commercial vehicles. The EU 6 standard presents a particular challenge for diesel engines.

The NOx emission for diesel engines will be limited to 80 mg/km and the overall HC-NOx emissions will be reduced by an additional 27% to 170 mg/km when compared with EU 5.

Two main technologies are being pursued by the automotive industry in parallel to fulfill such requirements. One approach is a cost-intensive filter technology for cleaning the exhaust gases; another is the increase in the overall efficiency, which provides additional benefit to the customer through reduced consumption. Both concepts need exact process control. A comprehensive set of sensors will be required to evaluate all relevant data. In addition to the exist68 | WIRE JOURNAL INTERNATIONAL

ing lambda sensors, further temperature sensors and various pressure sensors will be fitted. Exhaust gas temperatures will increase dramatically and a high accuracy of temperature measurement will be mandatory. Not only will temperature sensors need to be developed, the linked wiring system will also have to meet special requirements. Sensor cable designs such as thermo couple and compensation cables as well as extension cables will be used. All cable types are adapted to the thermo-sensor type and the relevant ambient conditions like high temperatures and chemical influences.

Conductor materials like NISIL (Ni-14.2Cr-1.4Si) or NICROSIL (Ni-4.4Si-0.1Mg) with defined thermo-electrical potential form the basis of such cable types. In addition to high-temperature insulation materials like PTFE, FEP or silicone are used for high-performance insulations.

Necessary EMI or mechanical protection issues can give rise to additional requirements; furthermore, automotive specifications need to be followed.

Comfort Even though the ecological focus is a clear trend today, many car buyers will not be willing to do without their comfort components. Comfort configurations like multimedia equipment, driver assistance and camera systems increasingly provide a competitive advantage. Although the data transfer in cars uses the same basic systems as other commercial products, the automotive industry requires a much higher cable performance due to high EMI influences and the requisite mechanical and thermal resistance. Quite often, special applications like mirror cameras will exert extensive stress on the data cables by, for example, bending and torsion loads caused by the movement of the mirror and door.

In spite of these influences, cables need to deliver outstanding data transmission performance.

Another challenge is the constantly increasing amount of wiring in the car. Space limitations result in the need for miniature designs as well as customised multifunctional cables, such as hybrid data cables. These special designs

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combine symmetrical data transfer cores with coax antenna cables, power cables and control wires. The target here is to reduce the mounting volume by integrating several functions within one cable design.

Miniaturization and weight reduction Increasing raw material costs, more functionalities, limited installation space in addition to environmental requirements are leading to a miniaturization of cables.

Comparing the number of copper cables in different cross sections from 0.35 mm² up to 80 mm² and their overall weight, the obvious conclusion is that the highest potential in weight saving lies in small cross sections of 0.5 mm² and below (signal Table 1: Copper cables: overview on number and weight per cross cables) and the large cross sections of section used in wiring harness. battery cables.

Miniaturization of signal cables.

An important point when looking at in the near future. Alternatives will need to be weighed up in the alternatives in the area of signal cables is mechanical the light of the field of application and the ambient condistrength. Certain tensile forces act on every single wiring tions. harness during installation. To avoid damage, most OEMs Battery cables should be looked at separately in this currently require the cable itself to have a minimum tensile respect.

While the issue of installation space plays a key role strength of approx. 70 N, which corresponds to the tensile as far as the whole cable loom is concerned, this is not necstrength of a 0.35 mm² soft copper wire. essarily the case with battery cables. Battery cables are in With this requirement in mind, reducing weight and instalmost cases not integrated into the main wiring harness and lation space by simply reducing the cross section is not an therefore allow the use of alternative conductor materials option with conventional, soft-annealed copper conductors. with lower density and less conductivity, such as aluminum.

Copper alloys with increased tensile strength present a clear Nevertheless, the weight reduction is achieved at the cost of alternative. Conductor materials like brass, bronze or copan increase in the conductor cross section. per-magnesium alloy allow a cross section reduction from Logically, electrical conductivity is a key aspect when 0.35 mm² down to as little as 0.09 mm². However, in the looking at the choice of alternatives in the area of battery short-term this minimized conductor cross section of 0.09 cables. When comparing the electrical conductivity of alumm² will not be used as single cores in cars as the cable minum and copper there is a 60% increase in the cross secitself, contacts and connector systems have yet to be certition of the aluminum conductor to ensure that the electrical fied. Cross sections of 0.22 mm², 0.18 mm² and also 0.14 resistance is identical to that of a copper cable. On the basis mm², on the other hand, are a realistic, short-term prospect of a cross section increase by a factor of 1.6 the weight savin cars as suitable contact systems are already available, ing it still works out, for the conductor itself, to about 50% some of which have been OEM approved. Besides alloys, Aluminum battery cables are now being used in a large composites-clad materials such as copper clad steel wire number of motor vehicles. The conductor cross sections (CCS) may also be used. range from 10 mm² to 160 mm². However, some properties The introduction of new materials and reduction of cross of aluminum represent important disadvantages: aluminum sections leads to a weight and space reduction in the harness, very quickly forms an oxide layer when exposed to air. provides a reduced dependency on copper price fluctuations Although this makes the aluminum itself highly corrosionand offers a significant contribution to saving our raw materesistant, it leads to problems when bonding. Furthermore, rial reserves. See Tables 2 and 3. aluminum shows a cold flow behavior when mechanical As discussed before, there will not be a general replacestress is applied that reduces the contact forces of a convenment of copper by one single alternative conductor material

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ous currents of up to 250 amperes are transferred using a high-voltage cable.

These high voltages and the electrical resistance of the conductor lead to a power loss which in turn results in the self-heating of the cable. Since only a small portion of the heat can be radiated to the surroundings, it is often necessary to use insulation and jacket materials that are resistant to high temperatures.

Starting with thermoplastic materials with constant operating temperatures of up to 125°C in pure electric vehicles to irradiation crosslinked compounds for 150°C applications through to special silicones for constant operating temperatures of up to 200°C, for example in the engine compartment of a hybrid vehicle, a comprehensive portfolio of materials is required. The cross section area of the conductor is just as varied, ranging from Table 2: Weight comparison of copper and aluminum with identical 16 mm² up to 70 mm², in specific cases cross section; and r, Table 3: Characteristics of copper and aluminum. even higher. Usually, manufacturers The high cross sections found in battery cables also provide room for resort to copper as a conductor material, improvement. which has proven its worth in the cable industry over the past few decades. Due to the current high cost of this metal and tional crimp interconnection over time. Another disadvanthe weight-saving potential on the high-voltage wiring systage is the differing electronegativity of aluminum and coptem, aluminum conductors are in some cases used as an per. When pairing metals of different electronegativity and alternative; however, because an aluminum cable has a lower adding an electrolyte, this will generally result in electroconductivity than a copper cable of the same conductor cross chemical corrosion. This decomposes the less pure metal, in section, this means that these high-voltage cables have a this case the aluminum. To avoid this corrosion an additionlower current-carrying capacity.

In order to ensure a compaal protection against humidity is necessary. Materials under rable performance, therefore, the aluminum diameters need discussion include grease, lacquers and resins. to be increased.

In most cases, the electric motor is connected via three parElectrification of powertrain: HV cables allel single-core cables, due to the restrictions of the instalAutomotive producers are facing the challenge of positionlation space. The use of electric motors operated with altering new generations of cars with hybrid or even purely elecnating voltage leads to a further requirement. Since electric tric drive systems on the market within a very short time in motors are controlled by power electronics with a high clock order to secure their position on the electromobility future frequency and steep edges, the high-voltage cables used market. The increasing electrification of the powertrain in must be additionally shielded in order to avoid possible EMI cars and commercial vehicles confronts OEMs and suppliers problems. High shielding effectiveness requirements across alike with new challenges and opportunities. a broad frequency range lead to a combination of different Regardless of whether it is a question of hybrid, fuel cell types of shield. or electrically powered vehicles, the battery must make However, it is not the drivetrain alone that must meet these available huge voltages to the different demands of the elecrequirements: the ancillaries within the high-voltage wiring trified system. In order to keep the power loss to a minimum, system—such as the air conditioning compressor, the addithe conventional low-voltage wiring system is expanded to tional electric heater and the DC/DC converter as the interinclude a high-voltage wiring system, which connects the face to the low-voltage wiring system—must also be includindividual components to the high-voltage battery. ed. For these two-phase connections, however, far lower curDepending on the system, the voltage can range between 80 rents of between 10 and 40 amperes are demanded from the volts (for example, electric vehicle MIA) up to 400 volts in high-voltage batteries. For this reason, substantially smaller passenger cars. Due to the higher power required in comcross sections of between 1.5 mm² up to a maximum of 6.0 mercial vehicles, voltages of up to 1,000 volts are used here. mm² are sufficient. Unlike the connection from the battery to In the powertrain, depending on motorization in the threethe power electronics and the electric motors, twin-core phase connection of one or several electric motors, continushielded cables are usually used in the ancillaries. If

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Charging infrastructure Along with electric vehicles, energy supply is a subject of high importance. The area-wide building of infrastructure has already begun in large conurbations of Germany and Europe. The experience gained from the pilot projects of energy supply companies (e.g. RWE, EON, Vattenfall) and carmakers (e.g. BMW and Daimler in Berlin, Renault in the Ruhr region) is feeding into the further development of technology and products. Charging electric vehicles is one of the challenges in this respect. Various scenarios for supplying the vehicle with energy are being discussed to solve the infrastructure issue. One option for charging the vehicle batteries is to provide charging stations. And here there is also debate over various different models for “filling up with electricity.” What is required here is that electric vehicles can be charged at home and at public electric charging stations in a fast-charge mode. Due to the various charging methods, differing charge currents involving different conductor cross sections also have to be taken into account. A version with a 16 mm² cross section would, for example in household use, be significantly oversized.

The charging cable is the point where the automotive world and the world of electrical engineering meet. The country-specific electrical engineering standards are the binding basis for the approval of charging cables. On top of this, there are often further requirements by carmakers.

First of all, it is important that the charging cable solutions cover the current charging connectors in accordance with IEC 62196 and the requirements placed on the conductive charging system in accordance with IEC 61851. However, at the international level there is as yet no consistently used, let alone uniform, technological standard.

The requirements placed on charging cables extend from single-phase and three-phase AC charging cables with currents of up to 63 amperes to DC charging cables in accordance with the Japanese CHAdeMO standard. Important characteristics of the cables are flexibility and feel.

Country variations Europe. In Europe and many other countries, China for example, the preferred versions are single-phase charging using domestic socket outlets or the three-phase fast charging with three-phase current up to 63 amperes. Typically, cables in the 750 V class in accordance with VDE with three or five cores and cross sections between 2.5 and 16 mm² are used to this end. On top of this, there is usually a signal core that provides the communication between the vehicle and the infrastructure. The cables can be used in temperatures ranging between -40°C and +90°C. In addition, fast charging using direct current is increasingly being discussed.

United States and Japan. In the U.S. and Japan, fast charging using three-phase current is not an option due to the conditions imposed by the local power distribution networks.

Consequently, their focus is on single-phase charging using domestic socket-outlets and on fast charging using direct current.

The cables require UL approval for the U.S, market. The range of services in accordance with NEC 400 comprises standard types EVJE and EVJT for voltages of up to 300 V and the larger, more robust cables of the EVE and EVT families for voltages up to 600 V. There is no limit on the cable cross section in this segment, so that DC charging cables with a correspondingly large cable cross section are also covered by it. For single-phase AC charging, the cross section of the three cores is typically 2.1 mm and is thus lower than in Europe. Here, too, there is usually an additional signal core that provides the communication between the vehicle and the infrastructure.

Conclusion Although the first car was born as long ago as 125 years, the innovative strength of the automotive sector remains as fresh as ever.

Dr. Klaus Probst is chairman of the management board of Leoni AG, Nuremberg, Germany. This presentation was made at CabWire World Conference, Düsseldorf, Germany, November 2011.

Probst

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required, they are supplemented with additional signal cores.

High-voltage automotive cables thus demand an extremely broad range of high-quality insulation materials and a range of manufacturing technologies from the cable manufacturers to match in order to do justice to all requirements in the hybrid or electric vehicle.

TECHNICAL PAPERS

TECHNICAL PAPER Commercial evaluation of TCHP dies Tests have shown that dies made with Tough Coated Hard Powders (TCHPs) provide longer life than traditional carbide drawing dies, offering multiple savings for steel wire manufacturers.

By John M. Keane and Roger N. Wright

Tough Coated Hard Powders (TCHPs) are a new family of patented, high performance metallurgical powders that incorporate unprecedented combinations of property extremes. They represent a class of engineered microstructure P/M based hardmetals having combinations of critical properties that provide improvements in performance and productivity. These engineered property combinations include toughness, abrasive and chemical wear resistance, low coefficient of friction, and light weight at levels not previously seen. TCHP powders can be fabricated into a multitude of industrial metal-cutting and wear parts to leverage their key attributes to achieve manufacturing productivity improvements. These TCHP powders are created by incorporating hard particles in a tough matrix using proprietary manufacturing technologies. Engineered nanostructures are designed by encapsulating extremely hard “core” particles with a tough outer layer(s), for example tungsten carbide and cobalt, which in the consolidation process becomes a contiguous matrix.

TCHP powders and consolidated die blanks are manufactured and sold by Allomet Corporation as EternAloy®.

TCHP processing, structure and properties have been described in previous publications1,2. Representative “core” particles include those traditionally used for extreme wear resistance (e.g., diamond, cBN, titanium carbonitride Ti(C,N), TiN, Al2O3, etc.). One typical TCHP material that uses alumina (Al2O3) as the core particle has been shown to be highly resistant to abrasive wear and is especially suited to wiredrawing dies and similar applications. Fig. 1 shows an example of an alumina TCHP grade microstructure.

Another recently developed EternAloy material utilizes core particles of Ti(C,N) which provide higher thermal conductivity along with high hardness, in a similar tungsten carbide and cobalt matrix. See Fig. 2. The Ti(C,N) TCHP grade offers significant performance advantages over the alumina TCHP in high-speed wire drawing where

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high heat generation at the die-wire interface rapidly wears WC-Co (carbide) dies. Allomet continues to develop additional TCHP grades to meet performance demands of more applications.

Fig. 1 shows SEM photos collected in backscattered electron mode (BSE) at 200X and 500X of the alumina TCHP consolidated structure. The dark circular areas in the microstructure are the hard, alumina core particles. Fig. 2 shows similar SEM photos of the Ti(C,N) TCHP consolidated structure. The dark areas in the microstructure are the hard, Ti(C,N) core particles. In both figures, the bright regions illustrate the WC and Co matrix.

Performance benefits of TCHP Under typical working conditions, such as those experienced at the die surface in high-speed wiredrawing or during high-speed metal cutting, the wear rate of the die/tool accelerates as it begins to soften and deform at the higher operating temperatures. Conventional WC-Co materials are limited by loss of hardness at these temperatures but TCHP materials retain their higher hardness at these higher temperatures due to the incorporation of hard “core” particles in the tough microstructural matrix. Different core particles impart varying thermal conductivity to the consolidated material as needed to meet demands of different wiredrawing and cutting tool applications.

The ability of TCHP grades to maintain high hardness at elevated temperatures is a key benefit that is unmatched by WC-Co parts. This is especially critical for high-speed machining using sintered TCHP cutting tools for achieving productivity gains (and higher metal removal rates) under challenging machining parameters. Managing and properly distributing the heat created during a wide variety of cutting conditions is important for determining the optimal application of TCHP inserts. Similarly, the higher hot hardness of TCHP grades, relative to WC-Co dies used in wiredrawing, enables a much longer die life and a more consis-

TCHP parts can also be ground and final shaped in the same manner as conventional tungsten carbide grades.

Additional applications include: round tools, nozzles, construction products, mining products, oil and gas, automotive, aerospace, various cladding applications and many other applications where wear resistance is critical.

In January 2010, Allometâ&#x20AC;&#x2122;s TCHP materials were selected as one of Wire & Cable Technology Internationalâ&#x20AC;&#x2122;s Top Products3. As Allomet expands its TCHP grade offerings to target many diverse applications, further mentions of its products for potential industry-changing productivity gains will emerge as publication of performance benefits continue to grow in the technical literature.

TCHP part fabrication

Product availability for die makers

TCHP powders can be consolidated into solid parts utilizing the same equipment and very similar processing parameters as conventional tungsten carbide materials.

Allomet has established the technology for TCHP powders to be pressed and sintered or sinterHIPped.

Producers of wire dies face a challenging and highly competitive environment as customers are seeking critical productivity gains. Increasing customer concerns about quality and customer willingness to try innovative solutions to improve quality and productivity are two important

Fig. 1. Alumina TCHP microstructure.

Fig. 2. Titanium carbonitride TCHP microstructure.

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TECHNICAL PAPERS

tent wire diameter throughout the spool.

The capability to resist crack propagation is another important attribute of TCHP grades. As shown in Fig. 3, an indenter was used to intentionally start a crack in a sintered alumina TCHP part; the resulting path of crack progression was then observed. It can be seen that the crack is deflected by, into and around the core particles. Thus much of the crack energy is partially absorbed by the core particles, resulting in a higher toughness material. Allomet has performed Palmqvist Toughness Tests on sintered TCHP materials and found higher toughness for both alumina and Ti(C,N) TCHP grades when compared with WC-Co grades of similar particle size.

TECHNICAL PAPERS

is seen to decrease as pressure increases and drawing speed increases. Basic drawing analysis allows average die pressure to be estimated as a function of die angle, drawing reduction and wire flow stress (strength). Nominal high carbon steel drawing parameters have been used in developing the die life comparison of Table 1, based on the seven-fold die life advantage displayed by TCHP dies.

Die cost estimating often employs the relationship:

Eq. (3) where C is the die cost per unit length drawn, T is the time required for die set change, B is the cost of labor and overhead per unit time, D is die set depreciation per use (inclusive of die costs, die refinishing costs, recut possibilities, etc.), and L is the length of wire drawn before die replacement is necessary. On this basis, a cost comparison has been made as follows:

Fig. 3. Resistance to crack propagation.

aspects for die producers. The EternAloy products address both of these issues and die companies that market this new technology should be able to develop new customers and gain significant market share in finished drawing dies.

EternAloy wire die blanks are available in ADDMA standard D-12, D-15 and D-18 disk sizes, as well as other typical ADDMA sizes (D6 to D24), and other standard or special sizes can be ordered. The EternAloy disks have been processed into finished wire dies by several die finishers using techniques similar to their existing processes for making finished PCD dies. Also, dies using EternAloy disks can be resized and reused several times similar to standard carbide dies, increasing their economic value.

Process economics Experience has shown that TCHP dies exhibit die life seven times that of conventional carbide drawing dies, and this increased life can have a major impact on process economics. Demonstrative process economics models have been presented in previous publications2,4. Standard wear equations lead to the relationship:

Eq. (1)

where t is die life, H is the hardness of the die material, δ is the die diameter increase due to wear, S is the drawing speed, P is the average die pressure and K is a proportionality constant. Eq. (1) can be simplified to:

Eq. (4) where (CWC-Co)/(CTCHP) is the ratio of WC-Co die cost to TCHP die cost, where DWC-Co and DTCHP are the die set depreciations per use, and where E is the product of T and B, which should be constant for the case of simple comparisons. Therefore, the relative costs of WC-Co and TCHP dies involves a tradeoff between increased die life for TCHP and the comparative values of die set depreciation.

The comparison of Eq. (4) involves the assumption that the cost of downtime (E = BT) during die replacement will be essentially the same for shorter and longer life dies. This certainly need not be the case, however. Consider that the projected TCHP lifetimes for the first three die positions (Table 1) generally exceed the drawing time expected for a month of three-shift production. For that matter, die positions four through seven could reasonably be inspected on a two-week basis. This implies that the dies could be inspected and replaced, as necessary, as part of a scheduled maintenance effort. Hence failure of such dies need not involve unscheduled interruptions in drawing productivity, and loss of time, T, in Eq. (3). The above considerations imply that the value of E in Eq. (4) should be considerably less for the TCHP case than for the WC-Co case, and it may be useful to restate Eq. (4) as:

Eq. (2) where Q is a “constant” (H δ)/(2K). Therefore, the die life

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Eq. (5)

Allomet’s initial TCHP grade, based on an Al2O3 core particle, exhibited extreme wear resistance and long life in wet wiredrawing, especially of 1070 steel. These EternAloy dies enabled performance that was seven times that of conventional WC-Co dies. Earlier trials at major carbon steel drawing houses have also indicated that the alumina TCHP has a lifetime roughly seven times that of WC-Co in several applications, with almost no change of wire diameter or shape over the life of the die.

Although this first Al2O3 TCHP grade is much more wear resistant and chemically inert than WC-Co dies, an upper limit to performance was discovered in some other applications, notably high-speed wiredrawing. The heat generated at the wire-die surface during very high speed drawing was isolated at that surface and not distributed through the alumina TCHP, which is a good thermal insulator. This did not result in rapid wear (in fact there was still very little wear) but on occasion this caused formation of small heat cracks that grew over an extended time.

Allomet developed a more thermally conductive grade of TCHP dies targeted for high-speed drawing based on a Ti(C,N) core particle. This new TCHP die complements the alumina TCHP grade but offers higher thermal conductivity and good toughness without sacrificing the abrasive wear resistance under conditions required for wiredrawing.

Both TCHP grades exhibit much better hot hardness than WC-Co grades. This provides higher deformation resistance under operating conditions with elevated temperature, which is important for improved performance in cutting tools but also permits very tight control of wire diameter.

The very low wear rate of TCHP dies allows them to last as much as 10 to 12 times or even longer than traditional WC-Co dies, depending on the heat generated during drawing conditions. Thermal management of heat generated during wiredrawing is an important consideration when determining the proper TCHP grade selection.

Allomet has developed some basic finite element modeling capabilities to predict specific grade performance to select the best available TCHP grade, and for design of new TCHP grades. This allows us to understand specific application requirements and to target appropriate performance improvements. For example, the temperature at the die-wire interface is a critical aspect for die life but it is very difficult to measure. Allomet’s modeling indicates that the interface temperature is higher than generally thought, even in wet drawing steel wire.

Fig. 5 shows an example of Allomet’s modeling of heat distribution during wiredrawing, with thermal simulations performed using ANSYS finite element software. In this process, a two- or three-dimensional structure is discretized into smaller “element” structures and boundary conditions are then applied to these elements. For this scenario, a heat flux across the die-wire interface, convection cooling and thermal material properties are all defined.

Analysis was done both as a function of time and under steady state conditions, as seen in the thermal model in Fig.

5, which shows the temperature profiles of a conventional WC-Co and a Ti(C,N) TCHP drawing die under identical conditions. As can be seen in the cut-away view of the die orifice and body, the TiCN TCHP die allows the heat generated during drawing to be better transported away from the wiredrawing zone and distributed throughout the die.

This reduces TCHP die wear even further, extending TCHP die life over WC-Co dies at higher drawing speed.

Industrial evaluations of TCHP dies Allomet has continued to progress with industrial wiredrawing applications and has done evaluation tests using TCHP dies only in the last several die positions and using entire lines of TCHP dies as well, confirming the results expected and described2. Allomet has tested complete lines of all TCHP dies at a major manufacturer in drawing 0.35 mm tire cord (1080) with excellent results. There was no wear in any upstream TCHP die and only very slight wear in the final die of the drawing line. This data confirms predictions of potential economic savings of improved die management programs for long life TCHP dies2.

Allomet was able to measure and document the wire diameters at the exit of every die position when the machines were stopped at the completion of a wire spool.

The dies were eventually replaced well before reaching their end of life and could be examined using optical and scanning electron microscopy. The upstream TCHP dies were removed after they exceeded a six-times the life multiple of WC-Co dies and did not show any discernable wear along either the approach or at the initial wire contact surface. The TCHP dies’ full capability is not known as they could still be used much longer, as predicted last year, and be treated essentially as maintenance instead of consumable supplies in many drawing operations.

In some of the smaller ID TCHP dies, the beginning of a wear ring was observed after five times the life of a typical WC-Co die. However, when these TCHP dies were later cross-sectioned, no significant depth to the wear rings was found. This indicates that TCHP dies at these positions could continue to perform for much longer as well.

Tested TCHP dies were sectioned through the center to evaluate the wear patterns and to investigate their performance characteristics. Both optical and scanning electron microscopy were used to assess the quality of TCHP microstructure, the quality of the TCHP die finishing and any wear characteristics or patterns in the tested dies.

Fig. 6 showns a cross-section of a tested TCHP die that was removed and cut in half to evaluate its condition after drawing approximately four times the predicted lifetime of a typical WC-Co die. The top SEM photo taken at 25X illustrates the TCHP disk and the wiredrawing channel.

The bottom SEM photo taken at 500X shows that the TCHP microstructure is intact, with little to no wear anywhere along the contact surfaces. Also visible in the photo are some minor scratch marks parallel to the drawing direction.

These test results indicate that Allomet has broken the die

AUGUST 2012 | 75

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New TCHP grades

TECHNICAL PAPERS

estimated in Table 1. Product development efforts are aimed at expanding the high speed capability of TCHP dies.

Prospects for further development

Table 1. Estimates of TCHP and WC-Co die lifetimes for drawing carbon steel with reductions of 15%, a die semi-angle of 6° and a final speed of 6 mps. lifetime barrier of standard carbide dies. The greatly extended die life of the TCHP products leads directly to opportunities for improved process economics, including advantageous new die maintenance and die replacement strategies from both engineering and financial viewpoints.

Allomet continues development of other TCHP grades that incorporate very hard particles, such as B4C and cBN. TCHP grades with these core particles will greatly expand the range of applications for TCHP materials within the cutting tool industry, as well as for wire dies and wear part applications.

Other planned EternAloy grade development includes TCHP materials based on diamond core particles. This will complement the existing TCHP die performance by further raising TCHPâ&#x20AC;&#x2122;s extreme abrasion resistance while at the same time offering the high toughness found in WC-Co grades. Further, a diamond TCHP grade will allow excellent thermal management of the heat generated at the wiredie surface and increase the wiredrawing performance window to compete favorably with diamond wire dies in many applications. The much higher toughness provided by the TCHP structure will differentiate it from conventional diamond dies.

Recommended application areas Recent trials at major carbon steel drawing houses have indicated that TCHP has a lifetime roughly seven times that of WC-Co in given applications. In wet drawing of steel tire cord, commercial evaluations of the product has so far shown more than six times the lifetime of WC-Co dies. TCHP dies have been particularly successful in applications such as drawing 1080 and 1090 steel at speeds up to 6-10 m/s, or less.

In very high speed applications, implementation of TCHP drawing dies at upstream, slower speed locations nonetheless can result in very long die lifetimes as those

Fig. 5. Temperature profile comparison.

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Fig. 6. Cross-section images of tested TCHP die.

TECHNICAL PAPERS

Summary The basic structure-property-processing aspects of TCHP materials have been reviewed. Commercial availability for drawing die applications has been noted and the process economics for these long-life dies have been presented.

Recent results from commercial drawing trials for fine, high-carbon steel wire have been summarized.

Recommendations for further applications and evaluations have been made, and prospects for further die material development have been cited.

References 1. R.E. Toth, J.M. Keane and I. Smid, Wire Journal International, Jan. 2008, p. 68.

2. J.M Keane and R.N. Wright, Wire & Cable Technology, May 2009, p. 52.

3. Wire & Cable Technology, Jan. 2010, p. 47.

4. R.N. Wright, Wire Technology, Process Engineering and Metallurgy, 2011, Butterworth-Heinemann, Elsevier, Oxford, p. 102.

Dr. John M. Keane is president of Allomet Corporation, a supplier of hardmetal, thermal spray, and specialty high performance powder products based in North Huntingdon, Pennsylvania, USA. Prior to joining Allomet, he spent 17 years with Valenite, a manufacturer of carbide cutting tools and wear parts, in technical management, new product development and technology transfer into manufacturing. He has more than 25 years experience in advanced materials development and materials characterization. He holds B.A. and Ph.D. degrees in chemistry and an MBA. He is a member of the American Chemical Society, SME, ASM, and has been inducted into Phi Lambda Upsilon (Chemistry Honorary Society) and Beta Gamma Sigma (Business Honorary Society). Professor Roger N. Wright, who joined the faculty at Rensselaer Polytechnic Institute in 1974, has contributed broadly to the literature in the areas of metallurgy and metals processing, and is active as a short course lecturer and consultant. He previously worked at Allegheny Ludlum Steel Corporation and Westinghouse Electric. He holds B.S. and Sc.D. degrees in metallurgy from Massachusetts

Keane

Wright

Institute of Technology. He has received The Wire Association Internationalâ&#x20AC;&#x2122;s (WAI) Mordica Memorial Award and the Schneider Memorial Award of the Poland Chapter of WAI, and is a four-time winner of the WAI Marshall V. Yokelson Memorial Award. He is a registered professional engineer, and a fellow of ASM and SME. This paper was presented at WAIâ&#x20AC;&#x2122;s 81st Annual Convention, Atlanta, Georgia, USA, May 2011.

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PRODUCTS & MEDIA PRODUCTS FEP FluoroFoam® masterbatch offers enhanced Cat. cable performance U.S.-based Cable Components Group (CCG) reports that during recent in-house trials, the company consistently ran its new FEP FluoroFoam® Masterbatch Compound (MBC) at 1800 feet per minute on 24 AWG copper wire, reaching an industry equivalent processing speed for solid thinwall FEP (0.007 in.) insulation for plenum cable (CMP) Cat. 5e and Cat. 6 wire primaries.

A press release said that the company’s chemically foamable FEP masterbatch, #CC301-26C-51P MBC, used with FEP in a 3-to-1 letdown, results in a 30% to 40% foam rate for thin-wall CMP insulations. The product reduces costs for cablemakers as well as a lower cable material footprint and improved electrical performance for both unshielded twisted pair (UTP) cables (Cat. 5e, 6 and 6a) and shielded (FTP) cables (Cat. 7), it said.

The release said that FluoroFoam is self-skinning, and that the chemical foam creates spherical small closed cells (less than 0.001 in. on average) ideally suited for a twisted-pair, thin-wall cable construction as its physical properties, including crush resistance, are excellent.

The release said that CCG also recently performed UL tests to compare and contrast flame and smoke results in the NFPA 262 Plenum Test (formerly UL 910), with the results shown in the table for a four-pair CMP Category 5e cable with all pairs foamed at 30% with FluoroFoam FEP and with AlphaGary’s standard plenum jacketing grades.

In the release, Tom Guida, a retired UL senior level wire and cable engineer who was a contributor to the NFPA and the evolution of the standard for plenum cables, assessed the results for CCG.

78 | WIRE JOURNAL INTERNATIONAL

Guida said in the release that the values for the FluoroFoam insulated cables of .07 average smoke, .016 peak smoke and one-foot flame spread were among the lowest he has seen for four-pair plenum cables in the UL burn test in recent years. “A competitive insulation grade, such as FluoroFoam...is long overdue to the market based on the myriad of marginally compliant plenum grade products that have recently entered the U.S. communication plenum cable market.”

Contact: Cable Components Group, tel. 860-5995877, www.cablecomponents.com.

Solar cable line is now offered in multiple sunlight-resistant colors SunGen®PV UL 4703 wire for solar applications from U.S.-based General Cable Wire is now available in an array of sunlight-resistant solid colors in all gauge sizes.

A press release said that the cable line, for solar applications from the sun to the outlet, has been engineered to meet changes to the National Electric Code (NEC®) that require photovoltaic (PV) source, output and inverter circuits to be identified at all points of termination, connection and splices. The SunGen PV UL 4703 wire provides installers with properly colored wire, eliminating the need for marking tape or tagging as a means of identification, saving time and money, it said.

“Giving contractors the ability to install colored PV wire improves efficiency by allowing them to meet NEC and UL requirements in a one-step process with wiring

Shipboard cables remain effective even in ultra-harsh Arctic conditions U.S.-based Northwire, Inc., has introduced its next-generation line of marine shipboard RIG wire and cable that it notes can perform well even in sub-zero environments.

A press release said that Northwire’s Extreme Frigid Flex Marine Shipboard RIG cable is ideally suited for applications in cold climates where extreme performance is required, space is limited and reliability is paramount. That,

it said, includes marine environments, such as for offshore and fixed oil rig cable and oil rig wiring needs and onboard marine vessels, fixed or floating offshore structures where marine grade wire and cable is required. The product, it said, offers superior bend flexibility across the dynamic temperature range of -60°C to 105°C, and is available with shield, over-braid, foil, composite and custom designs for 300-volt signal, 600 and 1,000-volt control and low power distribution.

The gauge range, the release said, is 22–2 AWG, and the product is over-mold and assembly compatible, able to be coiled for retractile marine wire and cable applications as well as being REACH and RoHS2 compliant, with approvals including UL 1309, CSA 245, IEEE 1580 and the American Bureau of Shipping (ABS). It added that the cable is approved for all colors for visual identification and has an abnormal low temperature impact of -40°C and is oil resistant to marine standards.

Contact: Northwire, Inc., www.northwire.com.

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that is manufactured with the very latest technology,” said General Cable’s Carrie Vidal, product manager, construction cables. Initial U.S. stocking is for popular circuit size constructions in both 600 V and 2000 V, as well as other available gauge sizes with low minimum-run requirements, it said.

The cable, the release said, offers superior resistance to UV sunlight while providing stable electrical properties for temperatures ranging from -40°C to 120°C. It noted that SunGen PV UL 4703 “is the only product on the market today that is made in accordance with both UL 4703 and CSA RPVU90, and meets the requirement for direct burial.”

Contact: General Cable, www.generalcable.com.

PRODUCTS & MEDIA

PVC elastomer compounds for auto charger cables are cost-effective At wire China 21012, U.S.-based Teknor Apex plans to introduce two Flexalloy® PVC elastomer compounds for charger cables for electric vehicles (EVs) that it reports offer more cost-effective alternatives to other elastomers in both insulation and jacketing.

A press release said that the two compounds are Flexalloy 89504-90, a 90 Shore A formulation for insulation, and Flexalloy 9610-78 for jacketing, with a Shore A hardness of 78. The materials, it said, exhibit brittle points of -46°C and -38°C, respectively, and both are rated for a maximum continuous operating temperature of 105 ºC. Unlike standard flexible vinyl, it said, the Flexalloy compounds are based on ultra-high molecular weight PVC resin. Per Mike Patel, wire and cable industry manager for the Vinyl Division of Teknor Apex, they exhibit improved toughness, abrasion resistance, and low-temperature properties and provide elastomeric resilience and resistance to compression set. The compounds can be processed on standard PVC equipment.

“Teknor Apex developed these two new Flexalloy products especially to meet the requirements of UL Type EVE for the high production volumes and rugged end use performance posed by EV charger cable,” Patel said. “They provide cost-effective alternatives to premium-priced elastomers such as TPUs.” Contact: Teknor Apex, tel. 401-725-8000, wirecable@teknorapex.com.

South Korean company reports it has developed a world-class fireproof cable South Korea’s LS Cable & System reports that it has that successfully developed a fireproof cable capable of withstanding temperatures up to 950°C, the highest temperature resistance ability of any cable in the world.

A press release said that the company succeeded in improving fire resistance to withstand temperatures 200°C higher than the typical 750°C (the upper limit of general fire-proof cables) by adding glass fiber and improving the properties of the mica used in the fireproof tape. It said that the cable can withstand 950°C for 80 | WIRE JOURNAL INTERNATIONAL

two hours and operate normally against the external impacts and exposure to water that typically occur during a firefighting situation.

The fireproof cable, the release said, meets International Engineering Consortium (IEC), British Standard (BS) and Normes Francaises (NF) standards, which it noted are far stricter than domestic fireproof standards. The cables, it said, can be used for emergency power supply when fire breaks out in ships, offshore structures and industrial facilities, and also for operation of key facilities and fire disaster prevention systems.

The release said that LS Cable & System has also developed a fire-proof cable for industrial structures and fireproof silicon insulated cable that is more flexible and easier to install and can be used in a wide variety of applications.

Contact: LS Cable & System, www.lscable.com.

Spark tester for cable insulation can even test itself for accuracy Germany’s Sikora AG reports that the company’s new SPARK 6030 HF is a high-frequency high-voltage sparktester designed for the detection of faults in the insulation as well as bare patches of cables from 0.5 to 30 mm.

A press release said that the model’s sturdy electrode and electronic box form one integral unit.

Optionally integrated in the device is a display that shows the number of highvoltage breakdowns.

The display, it said, is combined with a control panel for entering the test voltage.

During the extrusion of cables, the release said, the model inspects, detects and documents the insulation for possible insulation faults to ensure that only faultless cables are delivered, but it also has a very practical innovation: an integrated self-test and calibration system. That feature, it said, is important because European standards require regular checks of openly operated measuring and testing equipment with regard to high-voltage, short-circuit current and function (sensitivity). Previously, cable manufacturers had to use an external testing device, but the SPARK 6030 HF has an integrated three-step self-test and calibration system that performs this function, it said, noting that the model can “self-test” itself for its accuracy in measuring high-voltage of the device for correctness, for maximum short-circuit current and for its integrated function (sensitivity) test.

The SPARK 6030 HF has common interfaces as well as a W-LANinterface, and via W-LAN it can be directly connected to a smart phone or laptop, the release said.

Contact: Sikora International Corp., tel. 770- 4861233, sales@sikora-usa.com, www.sikora.net.

PRODUCTS & MEDIA

Double-twist buncher excels for medium-to high-voltage applications Italyâ&#x20AC;&#x2122;s OM Lesmo Group, which celebrates its 50th anniversary this year, reports that its unique double-twist bunching machines excel at producing compact aluminum and copper unilay conductors.

A press release said that cables can be produced using single-input wire sizes (SIW) of up to 61 strands unilay.

The innovative process uses an external capstan in conjunction with the double-twist machine to form a compact round conductor without using either different size input wires (combination strand) or pre-shaped wires, it said.

A typical setup includes stem payoffs, a lay-plate with die stand, an external capstan and a double-twist machine.

The double-twist buncher sizes, the release said, can be from DTO1600 to DTO2500 (1600 mm to 2500 mm takeup reel size). Using a unique cable path on the doubletwist bow allows a compact round unilay construction to be made three times faster than with a traditional rigid cabler, it said, adding that the company's patented singlebow design can reduce power consumption by about 20%. A wax application system positioned between the payoffs and the compacting dies assembly helps achieve higher compaction for aluminum, it said. The process can

produce unilay copper conductors up to 700MCM (350 sq mm) and unilay aluminum conductors up to 1000MCM (500 sq mm) as well as flexible strands, using either multi-wire payoffs or bunched members from a dynamic reel pay-off system, it said.

The company also offers a range of drawing equipment as well as auxiliary equipment, including batch annealing for aluminum.

Contact: Harish Panchal, OM Lesmo Group/Lesmo Machinery America, panchalh@comcast.net, tel. 603935-8992, www.omlesmo.com, www.lesmoamerica.com.

AUGUST 2012 | 81

PRODUCTS & MEDIA

Acid purification technology offers multiple advantages U.S.-based PRO-pHx, Inc., reports that its PRO- pHx acid life extender restores spent acid and extends acid life indefinitely.

A press release said that the acid purification technology, commercialized 11 years ago, uses a catalytic reaction that causes heavy metals and organics to become insoluble in any type of acid. The insoluble particles, it said, are then removed by a Siebec filtration system that can remove up to 10-12 kg of solids per L-TECH cartridge.

The cartridges are washable and reusable, and the high solids retention means longer filter runs, requiring less time devoted to changing the cartridges, it said.

The technology offers many advantages to a wire plant pickling with HCl, the release said. “Previously, acid concentrations were maintained at 160 g/l and the pickle tanks were purged periodically to control the iron at 80 g/l. Now, the HCl is maintained at 80-100 g/l and the iron concentration is maintained at 70-75 g/l with no blowdown. Lower iron and acid concentration are drug out into the rinses. Process savings are due to reduced virgin acid purchases, reduced caustic purchases for neutraliza-

82 | WIRE JOURNAL INTERNATIONAL

tion and reduced volumes of filter cake from the wastewater treatment system.”

PRO • pHx is sold through its network of authorized distributors, which includes representatives in all 50 states in the U.S., and most countries worldwide.

Contact: PRO-pHx, Inc., tel. 501-609-9808, prophxinc@aol.com, www.pro-phx.com.

MEDIA Website now offers more services for steel wire and strip users U.S.-based Gibbs Wire & Steel Co., has launched a new website, www.gibbswire.com, that provides a wide range of information about the company’s network of metal service centers that are strategically located throughout the U.S., Mexico and Canada.

A press release said that at the website, the ISO 9001:2008 certified distributor and custom processor of steel wire and strip provides metals buyers with quick access to tools and technical information to help in the purchasing process. Some of the new features include “Finished Cuts in Stock,” a daily-updated list of finished coil stock that can be purchased at a discount and shipped same day; the “Technical Tool Box,” which includes coil conversion calculators and a toll-processing calculator that provides information on which company locations can slit, edge or oscillate material for specific requirements as well as historical nickel information and technical bulletins for all company stock items; and a posting of the current monthly nickel/chromium surcharges.

“The Gibbs website will continue to evolve as we monitor our customers’ needs and market trends,” the release said. It added that individuals can also sign up for the “Gibbs Wire” newsletter via the homepage.

Contact: Gibbs Wire & Steel Co., www.gibbswire.com.

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WANTED: AGENTS MANUFACTURER SALES REPRESENTATIVES. Established US Manufacturer of welded wire mesh products looking for sales agents in the following global regions, Africa, Asia, Central America, the Caribbean, Europe, Middle East, North America and South America. Must work with complementary product lines in marine, fencing, fence security, cage, construction, farming/agriculture or reinforcement mesh.

For more information, please contact: jobs@riverdale.com.

WANTED: PRODUCT LINES MANUFACTURER’S REPRESENTATIVE. The Metallo Sales Group is seeking additional lines to represent in the wire industry. Our current lines are; copper alloy, wire, strip, rod and bar.

We have extensive experience in manufacturing and sales in the ferrous and nonferrous wire industry. For more information please contact us at: metallosales@msn.com or you can call: 802.368.2555.

PERSONNEL SERVICES “LET OUR SUCCESS BE YOUR SUCCESS” Wire Resources is the foremost recruiting firm in the Wire & Cable Industry. Since 1967 we have partnered with industry manufacturers to secure the services of thousands of key individual contributors and managers.

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622-3000 or (800) 394-WIRE. Visit our website at www.wireresources. com.

DIES APOLLO DIA-CARB COMPANY Sells Natural/PCD diamond dies.

Fair prices/excellent lead times.

Contact Paulette, Owner/Sales Tel. # 1 (508) 226-1508 or 1 (508) 226-0946 E-mail: apollodie@comcast.net AJEX - WIRE & COMPACTING DIES. Ajex & Turner offers a wide range of Wire Drawing and Compacting Dies for any size in PCD,

ND, Carbide and Nano at a very competitive price with a Conoptica Report.

We also make Extrusions Tools and machines for die polishing and regrinding and supply with die polishing accessories at free of cost. Kindly contact us by email: sales@ajexturner.com and visit our company’s website at: www.ajexturner.com.

MACHINERY WWW.URBANOASSOCIATES. COM. For New (Hakusan Heat Pressure Welders, Ferrous & NonFerrous; Marldon Rolling Ring Traverses) & Used Wire & Cable Equipment (buttwelders, coldwelders,

COMMISSION BROKERS, INC. EQUIPMENT SPECIALISTS TO THE ELECTRICAL WIRE & CABLE INDUSTRY APPRAISERS • COMMISSION BROKERS • INDIVIDUAL PIECES OR ENTIRE PLANTS

FOR SALE

1 - NIEHOFF Model SPH801.1.G.E.A Automatic Spooler 1 - NEB 12-C #2 Braider, Long Legs, Motor 3 - TMW 24-Carrier Cable Braiders, 6” Horn Gears 1 - EDMANDS 18-Wire, 6+12, 16” Planetary Cabler Line 2 - NEB Model C62-2 12-Wire 8” Vertical Planetary Cablers, 1987 1 - COOK 36” Cabler, Model R8 1 - PIONEER 50” Caterpuller Capstan, new belts 1 - SYNCRO F13 Rod Breakdown, refurbished 1 - DAVIS STANDARD 4.5” 24:1 L/D Extruder 2 - D/S 2” 30:1; 2.5” 24:1 L/D Hi-Temp Extruders 1 - WAYNE 1.5” 24:1 L/D Extruder 1 - SKALTEK 1600mm Motorized Payoff, Model A16-4K 1 - HALL 40” Motorized Payoff w/Dancer 1 - TULSA Model PO-10 Payoff, 1999 1 - CLIPPER DF6 Dual Cone Flyer Payoff (24” Reels) w/Reel Jacks 1 - BARTELL 12-Bay B64 Tubular Strander 1 - ROSENDAHL 630mm Parallel Axis Dual Reel Take-up, never used 1 - SPHEREX 18” Dual Reel Take-up, refurbished

1 - NOKIA Model EKP50 Parallel Axis Dual Reel Take-up, 1997 1 - CLIPPER Model SP16 Dual Spooler 2 - AL-BE Model MS12 Respoolers, 12” Reels 1 - REEL-O-MATIC Model PRR1 Rim Drive Powered Reel Roller 1 - REEL-O-MATIC Model RD-5 Rim Drive Takeup w/Coiling Head 1 - TULSA Model RD-10 Rim Drive Take-up, 1999 1 - WEMCO 84” Take-up, Model 8284B, w/Mobility Package 1 - TEC Model DTC630 D.T. Twister 2 - ENTWISTLE 4-Wire 24” D.T. Twisters, Model 4WDT24 1 - KENRAKE Model TWD101 Twister 1 - FINE Preheater, Model IP4000-180-1, 2007 1 - EUBANKS Model 4000-04 Cut and Strip Machine 1 - GETTIG Tape and Labeling System 3 - CARPENTER Strippers, Model 70-B 1 - MICRODIA Crosshead, Model M9000/10XFL 1 - DCM Electronic Switching System, Model ES350PC 1 - FORMULABS ‘Codemaster 5’ Spiral Striper, w/5’ Oven

Contact: Martin Kenner

COMMISSION BROKERS, INC. P.O. Box 8456 • Cranston, RI 02920-0456 • Tel. (401) 943-3777 • Fax: (401) 943-3670 WEB: www.commissionbrokers.com • E-MAIL: marty137@aol.com

AUGUST 2012 | 83

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NAME _________________________________________________________________________TITLE _________________________________________________ COMPANY ____________________________________________________________________________________________________________________________ ADDRESS ___________________________________________________________________________________________________________________________ CITY ________________________________________STATE _______________POSTAL CODE _____________________COUNTRY _______________________ PHONE ______________________________FAX________________________________EMAIL _______________________________________________________ AD CATEGORY____________ ISSUE YOUR AD BEGINS___________E-mail_____________________________________ NUMBER OF ISSUES RUN _______LAST ISSUE ________________RUN TILL FURTHER NOTICE? YES____ NO ____ FULL RUN (WJI & ON-LINE) YES____ NO ____

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color-o-meters and pointers). Tel: 727863-4700 or by e-mail, please send to urbassoc@verizon.net.

MACHINERY FOR SALE: CENTRIFUGES. Wire drawing coolant filtration - New and Used. Fully Automatic for Aluminum Wire, Copper Wire. MARS TECH PH: 845-6383100 email: sales@marstechusa.com

MEDIA THE ROEBLING LEGACY. This 288-page indexed book by Clifford W. Zink presents a different perspective of the Roebling legacy. “But it’s all wire,” proclaimed a 1950s Roebling Company brochure about its product line, which included wire rope, copper magnet and electrical wire, screens and hardware cloth, aircord and aircraft strand, flat

Please e-mail the requested information to: WAI’s Cindy Kirmss at ckirmss@wirenet.org.

For more details, you can call her at 203-453-2777, ext. 116.

and braided wire, PC wire and strand, galvanized bridge wire, among others.

To maximize quality, the Roeblings started drawing their own wire in the 1850s, rolling bars into rods in the 1870s, and making their own steel in the 1900s. Wire is the binding thread through 125 years of Roebling and American industrial history chronicled in The Roebling Legacy. The price is $75, $50 for WAI members, plus shipping. To purchase, go to wirenet.org and click on The WAI Store.

ELECTRICAL WIRE HANDBOOK SET. Focusing on the special needs of the insulated wire and cable industry, these books examine materials, equipment, and products. They include sections on electrical conductors, insulating materials, extrusion equipment, power transmission, building wire, flexible cords and cables, control and signal cables, communication cables, magnet wire, heater wire, and other applications. The set is divided into three separate handbooks. Part 1 is Wire and Cable Production Materials; Part 2 is Wire and Cable Production Processes, and Part 3 is Types of Cables. While the updated handbook includes the latest information available, this new format allows for more frequent future updates when necessary. Parts 1 and 2 are now available, but the original handbook will still be available until Part 3 is published separately. The price is $99, $59 for WAI members, plus shipping. To purchase, go to wirenet.org and click on The WAI Bookstore.

84 | WIRE JOURNAL INTERNATIONAL

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WIRE & CABLE MANUFACTURING

FASTENERS, WIRE FORMING, FABRICATING

WIRE END-USER

10 ❏ 20 ❏ 30 ❏ 40 ❏ 50 ❏ 53 ❏ 55 ❏

61 ❏ 62 ❏ 64 ❏ 66 ❏ 68 ❏ 69 ❏

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Aluminum & Aluminum Alloys (Rod/Bar, Bare Wire, Both ) Copper & Copper Alloys (Rod/Bar, Bare Wire, Both) Steel & Steel Alloys (Rod/Bar, Bare Wire, Both) Other Metal (Rod/Bar, Bare Wire, Both) Electrical Wire & Cable (Insulated Wire) Communications Wire & Cable (Insulated Wire) Fiber Optics

Fastener Manufacture Four-Slide Forming Hot and/or Cold Forming & Heading Spring Manufacture Wire Cloth Mesh Screening Other Forming and Fabricating (please specify): _________________________________

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B. Which ONE of the following best describes your primary job function?

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Fax to: (001) 203-453-8384 The Wire Association International, Inc. 1570 Boston Post Road | P.O. Box 578 | Guilford, CT 06437-0578 | Telephone: (001) 203-453-2777 | Fax: (001) 203-453-8384 | Web site: www.wirenet.org

Everything I needed to know about networking I learned at Wire Expo.”

I renew my WAI membership to stay on top of industry trends and new technology.”

Aaron Nolan

Andrew P. Helffrich

I can help WAI members learn more about copper, continuous casting, and process innovation.”

WAI’s networking summits propelled me to peak performance.”

Christine Lovett

WAI’s resources helped put the fun into hard work.

Seriously.”

Dane G. Armendariz

I can help WAI members look at operations today and see ahead to tomorrow.”

Bill Reichert

If you’re serious about a career in wire and cable, all signs point to WAI membership.”

Erik A. Macs

I joined WAI for the member discount on a technical conference and the investment paid off.

No regrets!”

Gary Spence

I can help people solve technical problems and improve their careers.”

Dr. Horace Pops

Paola D’Oria

DISCOVER WAI. Some things you know as well as your name. Other times it takes a little searching to find—or learn— what you need, especially if you are new to the wire and cable industry or plan to keep pace with its innovative advances.

Wire Association International (WAI) is the place to start.

As a WAI member it’s easy to stay informed. Likewise, you won’t have to dig too deeply to uncover the industry’s rich history and accepted certainties.

WAI members rank NETWORKING as the #1 reason to join.

When you consider that wire making can be traced on one timeline from the golden threads in ancient Egyptian jewelry—through telephony, countless creature comforts, and modern infrastructure— toward yet unimagined applications, you can appreciate your vital role in the wire manufacturing continuum.

WAI members represent a living history of the industry. Whatever your direction, if you earn a living with wire, cable, supplies, or equipment you’ve earned a place in WAI’s global network.

MEET YOUR PEERS. ACHIEVE YOUR GOALS. JOIN WAI TODAY. L E A R N

M O R E :

w w w . w i r e n e t . o r g

The Wire Association International, Inc. 1570 Boston Post Road | P.O. Box 578 | Guilford, CT 06437-0578 USA | Telephone: (001) 203-453-2777 | Fax: (001) 203-453-8384 | www.wirenet.org

ADVERTISER . . . . . . . . . . . . . .PAGE

ADVERTISER . . . . . . . . . . . . . .PAGE

Amaral Automation Associates . . . . . . . . . . . . . . . . . .79, 81

Fuhr GmbH & Co KG . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Amacoil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 3

Fushi Copperweld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Anbao Wire & Mesh Co Ltd . . . . . . . . . . . . . . . . . . . . . . . .81

Gauder Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

August Strecker GmbH & Co KG . . . . . . . . . . . . . . . . . . .39

GCR Eurodraw SpA . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 2

Bergandi Machinery Co . . . . . . . . . . . . . . . . . . . . . . . . . . .82

Gimax Srl . . . . . . . . . . . . . . . . . . . . . . .insert, between 16-17

Beta LaserMike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Howar Equipment Inc/Unitek . . . . . . . . . . . . . . . . . . . . . . .24

Caballe SA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Huestis Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12, 16

Carris Reels Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 4

Keir Manufacturing Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Cemanco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Lamnea Bruk AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Chemetall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Lesmo Machinery America Inc . . . . . . . . . . . . . . . . . . . . .31

Commission Brokers Inc . . . . . . . . . . . . . . . . . . . . . . . . . .83

Micro Products Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Dow Electrical & Communications . . . . . . . . . . . . . . . . . .25

Paramount Die Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

George Evans Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

Parkway-Kew Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Flymca & Flyro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

PolyOne Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Equipment Sales | Equipment Purchasing | Reconditioning Services www.wireandplastic.com | Info@wireandplastic.com

AUGUST 2012 | 87

ADVERTISERS’ INDEX

ADVERTISERS’ INDEX

ADVERTISERS’ INDEX

ADVERTISER . . . . . . . . . . . . . .PAGE Pressure Welding Machines Ltd . . . . . . . . . . . . . . . . . . . .53 Queins Machines GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Rosendahl Maschinen GmbH . . . . . . . . . . . . . . . . . . . . . .23 Sanxin Wire Die Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Sheaves Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Oct. 2012 WJI • CRU Analysis • Preview: IWCS Advertising Deadline: Sept. 1, 2012

SIKORA AG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Sjogren Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 Talladega Machinery & Supply Co . . . . . . . . . . . . . . .36, 47 Teknor Apex Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Tulsa Power Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Vandor Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Wire & Plastic Machinery Corp . . . . . . . . . . . . . . . . . . . . .87 Woodburn Diamond Die Inc . . . . . . . . . . . . . . . . . . . . . . . .58 Wyrepak International . . . . . . . . . . . . . . . . . . . . . . . . .20, 37 .

Zumbach Electronics Corp . . . . . . . . . . . . . . . . . . . . . . . .15

WIRE ASSOCIATION INTERNATIONAL ADS Interwire 2013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42-43 Interwire 2013: Call for Papers . . . . . . . . . . . . . . . . . . .61-62 WAI Membership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

WIRE JOURNAL

I N T E R N A T I O N A L

NORTH AMERICA

EUROPE

Robert J. Xeller Anna Bzowski Wire Journal International 1570 Boston Post Road P.O. Box 578 Guilford, CT 06437-0578 USA Tel: 203-453-2777 Fax: 203-453-8384 sales@wirenet.org

U.K., France, Spain, Holland, Belgium, Denmark & Scandinavia Jennie Franks David Franks & Co. 63 St. Andrew’s Road Cambridge CB4 1DH, England Tel/fax: 44-1223-360472 franksco@btopenworld.com

88 | WIRE JOURNAL INTERNATIONAL

SALES OFFICES ASIA/WAI INDIA OFFICE Germany, Austria, & Switzerland Dagmar Melcher Media Service International Spitzwegstraße 4 82402 Seeshaupt Germany Tel: 49-8801-914682 Fax: 49-8801-914683 dmelcher@t-online.de

India Wire & Cable Services Pvt. Ltd. (WCS) 501, Rainbow Plaza, S. No. 7 Pimple-Saudeagar Vil. Rahatani, Pune - 411017, India Huned Contractor mobile - +91 988 1084 202 hcontractor@wirenet.org

Wind up with an Amacoil/Uhing assembly for perfect pitch every time Pitch is adjustable (10:1) without requiring gear changes or adjusting motor speed. A single Amacoil/Uhing assembly may be used for winding many different diameter materials. Automatic reversal of the traverse is mechanically controlled – without clutches, cams or gears. No electronics or programming needed.

FEATURES • Zero backlash.

• Automatically synchronizes pitch with take-up reel rotational speed.

• Traverse drives with up to 800 lbs. axial thrust.

• Smooth, unthreaded shaft won't clog or jam – no bellows assembly needed.

• One inexpensive, unidirectional motor drives both the traverse and take-up reel.

• Free movement lever – no need to "jog" system on and off to position linear drive.

• Options and accessories for every winding situation.

• Light, medium and heavy-duty systems.

For Brochure or CD-ROM Call toll free 800-252-2645

email: amacoil@amacoil.com

www.amacoil.com AMACOIL, INC. PO Box 2228 • Aston, PA 19014 • Phone: 610-485-8300 • Fax: 610-485-2357