SPECIFICATION P-117: 88 (UDC 621.315.5:669) ALUMINIUM ALLOY STRANDED CONDUCTOR PAKISTAN WATER AND POWER DEVELOPMENT AUTHORITY DESIGN DEPARTMENT (T&G) POWERSPECIFICATION P-117:88 ALUMINIUM ALLOY STRANDED CONDUCTOR AMENDMENT NO. 2 DATED 12TH FEBRUARY, 1990 CLAUSE 3.1 Please add the sentence “The maximum value permitted 25 0.0328 ohm. mu2/m at 20°C" at the end of this clause. CLAUSE 3.4 ij Please add the word "a" at the end of the heading of this clause. il) Please add the word "a" after the words “coeffi- cient of resistance," in the second line of this clause, CLAUSE 9.5.4.1 Please replace the word "sampel“ in 3rd line with “sample. CLAUSE 6.4.1 i) Please replace the formula for resistence at 20°C (R20) as under:— gosh, - Pea (i307 ii) In Lhe second last line of this clause, please write the word "a" in the blank space which is after the word “and" & on the left side of the sign of equality. R20 Rt (- ) iii) Please replace “{ s 0.003 60)" with 9.00360)" in the last line of this clause after the words “of resistance”. Please replace the word "not" in 3rd tine with "no". CLAUSE 10.1 a) lease repiace the word " rigours". igors" in 4th line with i) Please add the sentence “the reels should be suit- able for tension stringing and capable to with stand its rigonrs” after 2nd sentence in the fifth line of this clause. iii) Please veplace the word "entachlorophenol” in 3rd ast line of this clause witn “pentachlorephenol™.iit DIMENSIONS Please replace the value "2200" for Nominal length of Caire Conductor with "2220" in table of fig te Please replace the value "4g9g" with "4593" fer Nominal weight of Greely Conductor in the table of fig 1.10. CONTENTS Foreword Scope Definition Standards for Aluminium Alloy Conductor Material Dimensions and Characteristics Test Methods Tests by Manufacturer Acceptance Tests Acceptance and Rejection Packing and Marking PRINTING HISTORY First approved on 15th July, 1979. First revised on Aprii, 1988. Amendment No. i Dated 12th February, 1990. 3999888 %SPECIPICATION P~117: 88 (UDC 621.315.5:669) ALUMINIGM ALLOY STRANDED CONDUCTORS POREWORD This standard specification has been prepared by the Besign Department Power Wing, WAPDA and lays down speci- fications for Aluminium Alloy Stranded Conductors. This specification is based on 1.8.C. 208 and ASTH B399 and is subject to revision as and when required. This specification is intended for procurement of material and does not include provisions of contract. SCORE This specification covers concentric layers stranded conductors, made from round aluminium alloy wires, for use as overhead conductors in polluted area. DEFINITIONS For the purpose of this specification the following defi- nitions shall apply. Stranded Conductor Conductor consisting of seven or more aluminium alloy wires of the same nominal diameter twisted together in concen tric layers. hen the conductor consists of more than one layer, successive layers are twisted in opposite directions. Diameter Mean o£ two measurements at right angles taken at the same cross-section. Direction of Lay The direction of lay is defined as right-hand or left- hand. With right hand lay, the wire conform to the direc~ tion of the central part of the letter "Z" when the con- ductor is held vertically. With left-hand lay, the wires conform to the direction of the central part of the letters "s" when the conductor is held verticall. Lay Ratio Ratio of the axial length of 2 complete turn of the helix formed by an individual wire in 2 stranded conductor to the external diameter of the helix. AX2.6 Heat-Treatment Batch Purnace load of material heat-treated at the sane time, at the sane temperature and for the same length of time. STANDARDS FOR ALOMINIUM ALLOY WIRES Resistivity For the purposes of this specification, the standard value of resistivity of aluminium alloy wire which shail be used for calculation is to be taken az 0.0325 ohn. maZ/m at 20°C. Density At a temperature of 20% the density of aluminium alloy wire is to be taken as 2.70 ka/dm?. Coefficient of Linear Expansion e The Coefficient of Linear expansion of aluminium alloy wire is to be taken as 23x10" per centigrade degree. Constant-mass Temperature Coefficient At a temperature of 20°C the "Constant-mass" temperature coefficient of resistance, , of aluminium alloy wire measured between two potential points rigidly fixed to the wire, is taken as 0.00340 per centigrade degree. MATERIAL (6201 Aluminium Alloy} The conductor chall be constructed of heat-treated alu- minium-magnesium-silicon alloy wires containing approxiz mately 9.5% magnesium and approximately 0.5% silicon and having the mechanical and electrical properties specified herein. The wires shall be smooth and free from all imperfections e hot Consistent with good commercial practice. The ultimate tensile stress of wire before or after stranding shall not be less than 30 kg/mmé. DIMENSIONS AND CHARACTERISTICS Standard Sizes The dimensions and characteristics of the conductor standardized for use by WAFDA and covered by this speci- fication are given in Table-I.SABLE DIMENSIONS AND CHARACTERISTICS OF ALUMINLUM ALLOY CONDUCTORS Cale bee code Stranding Dia of — lated Rated DoS. coes and wire complete area of ultimate [S3S57 weight aia conductor complete strength 8 at 20°C conducton no/me mim mm? kg ohms/it kg/km Aimoné 7/2034 7.02 30.10 903 1.084 82 Azoza 13.37 kos. 62.44 1873 0.527 ah Alliance 7/4.77 14.31 428.09 3753 (0.263 342 cairo 19/3.98 19.80 236.38 7091 0.140 630 meGreeley 37/4.02 28.14 469.80 13835 9,071 1295 5.2 folerance on Nominal Diameters of Wires 5.2.1 The aluminium alloy wires shall not depart from the nomina diameter by more than the following amounts. Woatnar Tolerance piameter — 2.501 sos & greater bess than 2.5 0k ++0.025m0 5.3 Joints in wires 5.3.1 Conductors Containing Seven wires There shall be no joints in any wires of a stranded con— ductor containing seven wires, except those made in the base tod or wire before final drawing. 5.3.2 Conductors Containing more than Seven Wires In stranded conductors containing wore than seven wires, joints in individual wires are permitted in any layer except the outermost layer (in addition to those made in the base rod or wire before final drawing) but no two guch joints shall be less than 15 m apart in the complete stranded conductor. Such joints shall be made by re- sistance butt-welding and shall, subsequent to welding, be annealed over a distance of at least 200mm on each side of the joint. They are not required to fulfill the mechanical reguirements for unjointed wires.8.4.4 Stranding The wires used in the construction of a stranded conductor shall, before stranding, satisfy all the relevant requirc- ments of this specification. The lay ratio of the different layers shail be within the limits given in Table-Ir. TABLE ~ IE Lay ratio for aluminium alloy stranded Conductors No. of Lay Ratio wires in Con- 6-wire Layer 12-wire Layer 18-wire Layer ductor min max min max min max 7 210 14 - - ~ - 19 10 16 10 14 - - 37 210 a7 10 16 10 44 In all constructions, the successive layers shall have opposite directions of lay, the outermost layer being right-handed. The wires in eacn layer shall be evenly ané closely stranded. In aluminium alloy stranded conductors having multiple layers of wires, the lay ratio of aay layer shall be not greater than the tay ratio of the layer immediately beneat! it. Calculatio of Conductor Properties The properties of the conductors have been calculated in accordance with clauses 5.5.2 through 5.3.4. Increase in Length due to Stranding When straightened out, each wire in any particular layer of 2 stranded conductor, except the central wire, is longer than the stranded conductor by an amount depending on the mean lay ratio of that layer. Resistance and Weight of Conductor Tae resistance of any length of a stranded conductor is the resistance of the same length of any one wire multi~ plied by a constant, as given in Table-II1. The weight of each wire in any particular layer of a length o£ stranded conductor, except the central wire will be greater than that of an equal length of straight wireby an amount depending on the mean lay vatio of that jayer (see 5.8.2 above). The total weight of any length of stranded conductox is, therefore, obtained by miltil plying the weight of en equal length of steaight wire by constant, as set cut in Table-TIT. SABLE - 173, STRANDING CONSTANTS Number of Stranding Constant wires in =r Conductor Herght 7 7,091 0.1447 19 19.34 0.09357 37 37.74 0.02787 Strength of Conductor Phe strength of a styanded conductor, in terms of the strengths of the individual component wires, may be taken tu be 952 of the sum of the strength of the individual wires calculated fromthe value of the minimum ultimate tensile stress givne in Sub-clause 4.3. For testing the ultimate strength of a complete stranded conductor, suitable fittings shall be applied to the ends of a sampel of conductor which shall be not less than 5m long and the assembly chali then be pulled in a suitable tensile testing machine. when so tested, the conductor shall withstand at least 95¢ of its strength calculated as indicated above. TEST MBrHODS Tensile vest This test shall be made on aluminium atioy wires prior to and after stranding. The breaking load of the specimen cut from the sample shall be determined by means of a tensile testing machine of which the accuracy can easily be chacked and to which adjustments can be made if necessary. When automatic tensile testing machine is used, the load shall be applied gradually and the rate of separation of jaws of the testing machine shall not be greater than Locam per minute. When a hand operated lever testing machine is used, 90% of the specified breaking load shall be applied quickly and the load shall then be increased steadily until thegecimen breaks. Q pazcent of the load shall be approximately 15 seconds nd the total time fom first application of lead to racture ghall be approximately 20 seconds. Re time kaken dn applying the last tha ea when tested before and after stranding, the ultimate tensile strengeh shall be not less than 36 ke/nm?. Elongation Test The englogation of a specimen tested as per clause 6.2 shali be determined as follows: The specimen shail be straightened »y hand and an original gauge length of 200m shail be marked on the wire. A tensile load shall be applied as described in clause 6.1 above and the e!ongation shall be measured after the fractured ends have been Fitted together. Tf the frac~ tured ende have been fitted together. If the fracture occurs outside the guage marks, or within 25mm of either marks, and the required elongation is not obtained, the test Shall be disregarded ana another test made. When tested before or after stranging, the elong be not less than 4% on a guage length of 200mm. on shal Wrapping fest Qhe aluminium alloy wire shall be wrapped round a manére} of diameter equal to the wire diameter to form a close helix of eight turns. Six turns shali then be unwrapped and again closely wrapped. The wire shall not break or show any cracks. Resistivaty Test Ghe electrical resistance of aluminium alloy wire shail be minimus to an accuracy of at least one part in a thousand. The length of the specimen shall be sufficient to give the accuracy required and sha]] ke suitable for the method of the testing used. The electrical resistance of one specinen cut from ea: of the samples taken from not less than 10¢ of the individual lengths of aluminiom alloy wire included in any one heat-treatment batch which will be included in any one consignment of stranded conductor, shall be measured at a temperature which shall be not less than 10°C and not more than 36°C. The measured resistanc: shall be corrected to the value at 20°C by means of formula: nh 1 Rog * Ry OE TE=2Oy6.4.2 Woere: 2 * Temperature of measurement R, = Lesistance at TC resistance at 20°C and conetant-wacs temperature coefficient ef resistance ( = 9,003 50 } whe resistivity at 20°C shall the: the resistance at 208C, the re not exceed 0.0323 ohm. xm2Z/m. be calculated from tivity at 290°C shali YESTS BY MANUFACTURER vel The manufacturer shall progressively carry out tests to waintain quality control and to ensure manufacture of conductor in compliance with the specification, such tests shall include the following, bub need not be res- tricted to them. 1) Visual Inspection 2) Verification of Dimensions 3) Yensile and Blengation Tests 4) Wrapping Tests 5) Resistivity Tests Visual inspection and verification of dimensions shall be carriod out as routine Leste on wires end complete conductors. sefore the start of manufacture tae base rod shail be tested for resistivity. One specimen shali he selected at random ont of every 102 of the lengths aluginiam alloy wire included in anyone consicnwent for test Material not conforming te the strnaded shall not be used. Yhe tensile strength and elongation tests shall pe carried out on wire finished to size bat before stranding. Samples shall be drawn From not less than 10 percent of the individua) lengths of aluminium alloy wire which will be {neluded in any one consignment. whe manufacturer shall maintain a record of all the tests carried out by him for examination by the authorized eepresentative of WAPDA. The manufacturer shall furnish a certificate to the effect that the aluminium ailoy stranded conductor manufactured by him conforms in all respects to the requirements of this standard. ACCEPTANCE TRSTS: g tests shall pe carried out on the aluca 1 10.4 8 alloy stranded conductor for acceptance. 3) Yisual Inspection 2) Verification of Dimensions 3) Tensile an@ Elongation Tests 4) wrapping Tests 5) Resistivity Tests ACCERYANCE AND REJECTION qhe manufactucer shall divide each consignment into tots for inspection. These lots shall be so selected that material in a lot is of reasonably uniform quality and as far as possible , is manufactured at the same tine and under the same conditions. the manufacturer shall keep sufficient production records to ensure that this can be done regularly. & lot may contain any number of @ lengths upto a maximum of 150. From each lot, regardless of its size, samples of wires shall be taken at random from approximately i0% lengths of stranded conductor included in any one consignment. One sample sufficient to provide one specimen for each teets, shall be taken from each strand of the conductor in each of the selected lengths. The samples taken shall be subjected te each of the prescribed in clause 8, The lot shal] be accepted, if for each test, the sample complies with the requirements of clauses 9.4 and 9.5. if in any test three or more specinens f2il, the entire tot shall be rejected. 1f two specimens fail in any tests, a further sample in accordance with clause $.2, shall be taken fre the lot, and the particular tests repeated. If there are not e further failures the sample shali be considered accept~ able for the test. I€ im any test three or mora epegimens fail, the entire let shall be rejected. The manufacturer shall afford to the inspector all necessary test facilities and assistance for carrying out the tests. The failities shail be provided free of charge. PACKING AND MARKING Aluminium alloy stranded conductor shall be sugplied on stranded wooden reels as per fig. i. The reels shail be nade fom high auality wood anc shall be of sound construction, able to withstand the usual rigors of transportation and field construction. The complete10.4 y of the reels apart frow being orotected b. en lagging nailed at each end of the reek as per £iq 1, shall also be bound by two straps. The weoden recis shal? be given two brush suats of 8 percent entacnlorophennot solution in cd before winding of conductor. Tne conductor shall pe wound tightly. reel The conductor shall be supplicd in lengths specified fig 1. ach reel shal] contain either one or two ths only as specified. A tclerance of plus or minus 5 percent is permitted on the conductor length. Addi- tionally it snail be persissible to supply not more shan 5 percent of the lengths on any one order in random jengths, none of which shail be shorter than one third of the nominal length. fhe manufacturer shall vrovide the following markings om the reels in legible ang indelible letters. 2) Manufacturer’s nam nd dasignation 2) Conductor designation 3} Address of the consignee and purchase order number 4) Serial number of the reel the manufacturer shall stamp the Eollowing information on metallic plates which shall be secureiy nailed to the real, i) Size and designation of aluminium alloy stranded conductor 2) Net weight, tare weight and weight, in ke. 3) Total length of the conductor on the reel , in meters 4) Serial numher of the reel. of the reel shall have an arrow marking the i ion of rolling. \SiEEL $TRA: SWIDTH 20 ota 1 MANUFACTURER'S NAME . AND BES'GNAr! oN UEOR DESIGN, WEW SIDE VIEW — “STONSIGNEE'S ADDRESS & LSERISL NUMER OF REEL PURCHASE Of NUMBER Reel Piangé | Flange | Drum|thside) Arbor | tanging [Norminall Rox Conductor|lDesigny Bia fThicknesd Bia. [Width | Hole # Thiclmess Length | Height of lation | L 1M G Motors | CoMductor [em shai aa | eg ~ | i Wr Aieore RRL | sie i sO | Bet7eo | 279 | Azoza |raao7e | a7 so | axt600 | i ! Alliance |ssaa70 | 70 80 —P caine femaseo | a5e0 | 80 j renazoe | 2200 | 80