Southwire Company Overhead Conductor Manual
First Edition
Edited by
Ridley Thrash,
Chief Engineer, Overhead Conductors
Gerald Hudson,
Manager of Metallurgical Quality
Dave Cooper
‘Testing Engineet
Gene Sanders
St. Development Engineer
Southuvire Company
One Southwire Drive
Carrollton, Georgia, 30119
404-832-4242 ii
FIRST EDITION/FIRST PRINTING
Copyright © 1994 Southycze Company
“This publication isa collection of items of general information related to the subject of overhead power dis
tuibotion conductors, It isnot intended tobe, nor should it be used as, authority for design, construction, or
‘se of such conductors, The design, construction and the use of such conductors should only be undertaken
by competent professionals in ight of curently accepted design and engineering practices.
‘While great car has been employed to ensure thatthe tables and formulas contained herein are free of
errors, absolutely no warranties, whether expressed or implied, ae made as to the acuracy or completeness
of any such tables and formulas contained herein.
“Those preparing andjor contributing to this publication specifically disclaim any warranty of any kind,
whether expressed or implied. The warranties of merchantability and fitness for a particular purpose are
bhereby disclaimed by Southwire and all other parties involved inthe creation, produetion, or delivery of the
publication.
‘Neither Southwire, Power Technologies, Ine, or anyone else who has been involved in the creation, pro
duction, or delivery ofthis publication shall be liable for any direct, indirect, consequential, or incidental
damages asing out of the use the results of the use, o inability to use such publication even if Southwire
Jha been advised ofthe possibility of such damages or claim. Some states dono allow the exclusion or lim
tation for consequential or incidental damages, 50 the above limitation may not apply to you.
Some figures were reprinted with the permission of IEEE from IEEE Std. $24-1992, IEEE Guide to the
Installation of Overhead Transmission Line Conductors, copyright © 1992 and IEEE Std, 563-1978, TEEE
Guide on Conductor Self Damping Measurements, copyright © 1978, published by the Institute of Electrical
‘and Electronics Engineers nc. The IEEE takes no responsibility for and will assume no liability fr damages
resulting from the reader's misinterpretation of sid information resulting from the placement and context in
this publication. Information is reproduced with che permission of the IEEE
Southwire also acknowledges and appreciates the receipt of information from the following organizations.
Individual references ae contained within the txt.
‘Alcoa Conductor Products Company
‘Aluminum Assocation
‘American Society of Civil Engineers
“American Society of Testing and Materials
(Canadian Electrical Assocation
lecric Power Research Institute
Fargo Manufacturing Company
Institute of Electrical and Electronics Engineers
McGraw-Hill
[ational Electrical Code
[National Oceanographic and Atmospheric Administration
Power Technologies, Ine
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a uononponuy Table of Contents
1.0 Introduction to Bare Overhead Conductors
1.1 Types of Conductor Materials,
12
13
15
16
a7
1.11 Aluminum and Aluminum Alloy Wire
1.1.2 Medium- and High-Strength Steel Wite
1.13 Selected Physical and Mechanical Properties
1.14 Mechanical Properties of 1350 and 6201 Wire
1.15 Mechanical Properties of Steel Wire
Concentric-Lay-Stranded Conductor Construction
1.2.1 Round-Wire Construction
1.2.2 Trapezoidal-Shaped-Wire Construction
1.2.3 Stranded Conductor Size
1.2.4 ACSR Stranding Ratios
Electrical Characteristics of Conductors
1.3.1 DC Resistance
1.3.2 AC Resistance
1.3.3 Inductance and Inductive Reactance
1.3.4 Shunt Capacitance and Capacitive Reactance
Mechanical Characteristics of Stranded Conductors
1.4.1 Rated Strength of Concentric-Lay Stranded Conductors
1.4.2 Stress-Strain Characteristics of Stranded Conductors
Thermal Rating of Bare Overhead Conductors
Conductor Selection
1.6.1 Standard Conductors
1.6.2. Modified Conductors
References
Chapter 1 Appendix
Conductor Tables
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3.0. Thermal Ratings of Bare Overhead Conductors
34 Steady-State Thermal Ratings
3.1.1 Steady-State Calculation Methods
3.1.2 Steady-State Heat Balance
3.13 Solar Heat Gain
3.1.4 Conductor Ohmic Loss
3.15 Convection Heat Loss
3.1.6 Radiation Heat Loss
3.1.7 Ambient Conditions
3.1.8 Conductor Variables
3.1.9 Steady-State Thermal Rating Calculations
3.1.10 Computer Calculations of Thermal Ratings
3.2 Transient Thermal Ratings
3.2.1 Step Increase in Load Current
3.2.2 Conductor Heat Capacity
3.2.3 Example of Emergency Thermal Rating Calculation
3.2.4 Thermal Time Constant
3.2.5 Fault Current Ratings
3.3 Loss of Strength at High Temperature
3.3.1 Annealing of Individual Strands
3.3.2 Conductor Loss of Strength
3.33 Calculation of Remaining Strength
‘Sag at High Temperatur
3.4.1 Thermal Coefficient of Expansion
3.4.2 Suspension Span Interaction at Elevated Temperature
3.5 High-Temperature Creep Elongation
3.5.1 Creep of AAC, AAAC and ACAR Conductors
3.5.2 Creep of ACSR Conductors
3.53 Creep Calculation Example
3.6 Effect of Elevated Temperatures on Line Hardware
3.7 References
Chapter 3 Appendix
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Design of New Transmission Lines
‘New Transmission Line Design Considerations
5.1.1 System Requirements
1.2 Environmental Design Constraints
5,1.3 Standard Line Design Considerations
Electrical Insulation Coordination
5.2.1 Power Frequency Design
5.2.2 Switching Surge Flashover
5.2.3 Lightning
Wind-Induced Conductor and insulator Motions
5.3.1 Conductor Blowout
5.3.2 Aeolian Vibration
33 Ice Galloping
5.3.4 Subconductor Oscillation
Economic Design of Overhead Lines
5.4.1 Present Worth [PW] of Electrical Losses
5.4.2 Capital Construction Costs
5.4.3 Minimizing Total Line Cost
5.4.4. Supporting Structure Cost Models
5.4.5 Conductor Selection With the Typical Span Method
5.4.6 Economic Structure Spotting
5.4.7 Optimization with Respect to Conductor Tension
References
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‘Thermal Uprating of Existing Lines
‘Selection of Method for Uprating
7.1.1 Present Limitations
7.1.2 Major Economic Factors
7.13 Physical and Institutional Constraints
Determination of Thermal Ratings for Overhead Lines
7.2.1 Thermal Rating Parameters
72.2. Thermal Rating Terms and Definitions
7.2.3 Exact Heat Balance Equation
72.4 Approximate Thermal Rating Calculations
Influence of Primary Variables on Thermal Rating Calculations
726 Influence of Secondary Variables on Thermal Rating Calculations
Approaches for the Thermal Uprating of Existing Lines
7.3.1 Reassessment of Weather Parameters for Static Ratings
7.32. Real-Time Thermal Rating of Overhead Lines
733 Increasing the Maximum Allowable Conductor Temperature
7.34 Modifications to Sag-Limited Lines
7.35 Reconductoring Existing Transmission Lines
References
Chapter 7 Appendix
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PBOUIDAO oreg
0} UOT}ONpoIyUy Introduction to
Bare Overhead
Conductors
In the line design process, the most critical decision
often involves selecting the phase and ground conduc:
tors. Phase conductors are energized and carry all the
electrical load current, At higher transmission voltages,
there may be as many as four conductors for each elec:
trical phase of each circuit. There are usually no more
than two ground conductors. They are normally not
energized, but are present to divert lightning strokes to
ground.
Conductors usually comprise 20 to 30% of the mate-
rial and labor costs of a line. The selection of conduc-
tors is critical since the wind, ice and tension loads
that supporting structures must withstand are depen
dent on the size and type of conductors used. Structure
heights are also largely dependent on the conductors
selected since maximum sag of phase conductors under
maximum ice or maximum temperature conditions is
governed by certain physical, mechanical and dimen
sional properties of the conductor. Even environmental
effects, such as radio noise and audible noise, are heav-
ily influenced by the conductors themselves.
Phase and ground conductors rormally consist of mul-
Liple staands of alurninur, copper, andfor steel, though
the use of copper is uncommon in modern transmission
lines. Bare overhead phase conductors are usually classi-
fied as homogeneous or non-homogeneous. Homoge-
neous conductors are those in which the individual
strands of wire composing the cable are of the same
material, Homogeneous conductors manufactured with
relatively pure aluminum are called all-alumimam con:
ductors (AAC); those manufactured with an aluminum
alloy are called all-alurninum-alloy conductors (AAC).
Non-homogeneous conductors consist of mixtures of
different wire materials. The most common type of
bare overhead phase conductor is a non-homogeneous
cable consisting of aluminum strands covering a steel
core, This conductor is called aluminum conductor,
steel-reinforced (ACSR). Another non-homogengous
conductor is one composed of a mixture of relatively
pare aluminum strands and aluminum alloy strends
This conductor is referred to as aluminum conductor,
alloy-reinforced (ACAR).
The stranded conductors have physical, mechanical
and electrical properties that reflect the properties of the
{individual strands of wire that comprise the conductors.
The properties of homogeneous cables quite naturally
parallel the properties of their singular-type individual
wires, Non-homogeneous conductors, however, possess
‘Properties that reflect the individual properties and rela-
tive percentages of the different materials forming the
composite cable. Due to the stranding-induced helical
form of the individual strands, both types of conductors
exhibit lower composite rated breaking strength (4 to
11%), greater weight and higher resistance per unit
length of conductor (2 to 4%) than would be obtained
were all the component wires parallel.
Selection of the best conductor for a particular trans
mission or distribution line depends upon many factors,
such as power requirements, terrain, ambient candi
tions, costs of the conductor and supporting structures,
and governmental and environmental constraints In
addition to the strength and electrical resistance of the
conductor, pertinent properties of interest include the
stress-strain relationship, thermal characteristics, and
inductive and capacitive reactances. Since each over-
head line presents a unique set of requirements, an
array of conductors ranging from standard AAC,
AAAC, ACAR and ACSR to high-temperature types to
vibration-resistant designs have been developed to meet
the needs ofthe electrical utility industry.
orotet cee aaes Q)
Hr Introduction to
Bare Overhead
Conductors
In the line design process, the most critical decision
often involves selecting the phase and ground conduc:
tors. Phase conductors are energized and carry all the
electrical load current. At higher transmission voltages,
there may be as many as four conductors for each elec
trical phase of each circuit. There aze usually no more
than two ground conductors. They are normally not
energized, but are present to divert lightning strokes to
ground.
Conductors uswally comprise 20 to 30% of the mate:
rial and labor costs of a line. ‘The selection of condue-
tots is critical since the wind, ice and tension loads
that supporting structures must withstand are depen:
dent on the size and type of conductors used. Structure
heights are also largely dependent on the conductors
selected since maximum sag of phase conductors under
maximum ice or maximum temperature conditions is
‘governed by certain physical, mechanical and dimen-
sional properties of the conductor. Even environmental
effects, such as radio noise and audible noise, are heav
ily influenced by the conductors themselves.
Phase and ground conductors normally consist of mul-
tiple strands of aluminum, cepper, and/or steel, though
the use of copper is uncommen in moderna transmission
lines. Bare overhead phase conductors are usually classi-
fied as homogeneous or non-homogeneous. Homoge-
neous conductors are those in which the individual
strands of wire composing the cable are of the same
material, Homogeneous conductors manufactured with
relatively pure aluminum are called all-aluminum con:
ductors (AAC); those manufactured with an aluminum
alloy are called al-aluminurm-alloy conductors (AAC).
Non-homogeneous conductors consist of mixtures of
different wire materials. Tie most common type of
bare overhead phase conductor is a non-homogeneous
cable consisting of aluminum strands covering a steel
core. This conductor is called aluminum conductor,
steel-reinforced (ACSR). Another non-homogeneous
conductor is one composed of a mixture of relatively
pare aluminum strands and aluminum alloy strands.
‘This conductor is referred to as aluminum conductor,
alloy-reinforced (ACAR).
The stranded conductors have physical, mechanical
and electrical properties that reflect the properties of the
individual strands of wite that comprise the conductors.
‘The properties of homogeneous cables quite naturally
parallel the properties of their singular-type individual
wires. Non-homogeneouss conductors, however, possess
properties that reflect the individual properties and rela
tive percentages of the different materials forming the
composite cable. Due to the stranding-induced helical
form of the individual strands, both types of conductors
exhibit lower composite rated breaking strength (4 to
11%}, greater weight and higher resistance per unit
length of conductor (2 to 4%) than would be obtained
were all the component wires parallel.
Selection of the best conductor for a particular trans
nission or distribution line depends upon many factors,
such as power requirements, terrain, ambient condi-
tions, costs of the conductor and supporting structures,
and governmental and environmental constraints. In
addition to the strength and electrical resistance of the
conductor, pertinent properties of interest include the
stress-strain relationship, thermal characteristics, and
inductive and capacitive reactances. Since each over:
head line presents a unique set of requirements, an
array of conductors ranging from standard AAC,
AAAC, ACAR and ACSR to high-temperature types to
vibration-resistant designs have been developed to meet,
the needs ofthe electrical wtlity industry
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