Engineering Specification – Electrical

MESP 130500-01

TECHNICAL SPECIFICATION FOR

CONTACT WIRE HARD-DRAWN

COPPER 161mm2

Version: 2
Issued: May 2018

Owner: Engineering
Approved by: Andrew Russack, Head of Engineering Electrical
 ELECTRICAL NETWORKS SPECIFICATION
CONTACT WIRE HARD-DRAWN COPPER 161mm2
MESP 130500-01
Version: 2 Effective from: 2nd May 2018
L1-CHE-SPE-001

Approval

Amendment record

Approval Date Version Description

Initial issue under MTM. This document replaces Mainco
Specification MESP 0002 Revision A. Rebranded &
19/09/2011 1 reformatted to reflect MTM. Reference to EN 50149 removed
(does not specify the characteristics of 161mm2 copper alloy
wire).
Normal conductor tension in Appendix A corrected from 20kN
to 15kN
02/05/2018 2
Reference to 310 UTS removed from Appendix A. Minimum
UTS remains unchanged at 325 MPa.

Approving Manager: Head of Engineering Electrical Approval Date: 02/05/2018 Next Review Date: 02/05/2021
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 ELECTRICAL NETWORKS SPECIFICATION
CONTACT WIRE HARD-DRAWN COPPER 161mm2
MESP 130500-01
Version: 2 Effective from: 2nd May 2018
L1-CHE-SPE-001

Table of Contents

1 Scope of work .......................................................................................................4

2 General information..............................................................................................4

3 Standards ..............................................................................................................4

4 Material ..................................................................................................................4

5 Dimensions ...........................................................................................................5

6 Production test requirements ..............................................................................5

6.1 Mechanical tests .................................................................................................... 5

6.2 Tensile .................................................................................................................... 5

6.3 Elongation .............................................................................................................. 5

6.4 Torsion.................................................................................................................... 5

6.5 Bend ........................................................................................................................ 6

6.6 Electrical resistivity test ........................................................................................ 6

6.7 Retests .................................................................................................................... 6

7 Quality Assurance ................................................................................................6

8 Warranty ................................................................................................................6

9 Packing ..................................................................................................................7

10 Appendices ...........................................................................................................8

Appendix A: Conductor characteristics (informative information) .......................... 8

Approving Manager: Head of Engineering Electrical Approval Date: 02/05/2018 Next Review Date: 02/05/2021
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 ELECTRICAL NETWORKS SPECIFICATION
CONTACT WIRE HARD-DRAWN COPPER 161mm2
MESP 130500-01
Version: 2 Effective from: 2nd May 2018
L1-CHE-SPE-001

1 Scope of work
The scope comprises the manufacture, testing, supply and delivery of 161 mm² hard-
drawn copper contact wire in accordance with this specification and to the entire
satisfaction of Metro Trains Melbourne.

2 General information
The contact wire is required for the overhead traction supply to the 1500 V dc
metropolitan railway system. The conductor will generally be used with pantograph
type carbon (metalised) current collectors.

3 Standards
The latest revision of the following Standards are to be referred to:
AS/NZS 1574 Copper and copper alloys – Wire for electrical purposes

AS 2738 Copper and copper alloys – Compositions and designations of

refinery products, wrought products, ingots and castings

AS 2193 Calibration and classification of force-measuring systems

AS/NZS 2857 Timber drums for insulated electric cables and bare conductors

AS 1391 Metallic materials – Tensile testing at ambient temperature

AS/NZS ISO 9001 Quality management systems – Requirements

IEC 60468 – 1974 Method of measurement of resistivity of metallic materials

4 Material
4.1 The chemical composition of the material used for the solid conductor shall conform
to AS 2738 alloy designation C11000 (Electrolytic tough pitch copper).
4.2 The maximum resistivity at 20 °C is 0.01777 microhm-metre (equivalent to a
conductivity of 97% IACS). For a solid conductor of 161 mm² cross-sectional area,
this equates to a maximum resistance of 0.1125 ohms/km @ 20 °C.
4.3 The minimum ultimate tensile strength is 325 MPa for the finished hard-drawn copper
wire.
4.4 The wire shall be clean, smooth and free from harmful defects.
4.5 Joints are not permitted.
4.6 The wire density at 20 °C shall be 8,890 kg/m³ plus or minus 3%.

Approving Manager: Head of Engineering Electrical Approval Date: 02/05/2018 Next Review Date: 02/05/2021
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 ELECTRICAL NETWORKS SPECIFICATION
CONTACT WIRE HARD-DRAWN COPPER 161mm2
MESP 130500-01
Version: 2 Effective from: 2nd May 2018
L1-CHE-SPE-001

5 Dimensions
Wire size and shape shall be in accordance with Railway Overhead Drawing D3228
(contains reference to this specification), Revision A, for 161 mm² contact wire. The
wire tolerances shall be as per drawing.

6 Production test requirements

For the purposes of the tests specified in Clauses 6.1 and 6.2 a sample shall be cut
from each length (drum) of wire. The sample shall receive no treatment before testing
apart from straightening if necessary.

6.1 Mechanical tests

The testing machine shall be of suitable capacity and to an accuracy specified in AS
2193. The machine shall be mutually acceptable to Metro Trains Melbourne and the
supplier or their representatives.

6.2 Tensile
The breaking load of each sample shall be determined in accordance with the method
given in AS 1391. The ultimate tensile stress shall be calculated on the basis of the
actual cross-sectional area of the wire before testing.

6.3 Elongation
The load shall be applied to straightened lengths of wire having an original gauge
length of 200 mm in accordance with the methods described in AS 1391. The minimum
elongation on a gauge length of 200 mm is 3.0%.

6.4 Torsion
The test piece shall withstand 5 complete 360° twists in a 250 mm gauge length
without breaking or showing any seams, pits, slivers or other surface imperfections of
sufficient magnitude to indicate inherent defects in the wire. The machine used for the
test shall be so constructed that there is a linear motion of the tailstock with respect to
the head.
The test shall be conducted as follows:
A length of 300 mm shall be held between the grips of the testing machine and a
length of 250 mm marked off centrally between the holders.
Half the number of turns shall be made on the full 300 mm length, after which the test
piece shall be re-gripped so that the marked length can be tested to destruction. In
determining compliance with this specification the number of turns on the 250 mm
gauge length shall be counted. The rate of twisting shall not exceed 20 turns per
minute.

Approving Manager: Head of Engineering Electrical Approval Date: 02/05/2018 Next Review Date: 02/05/2021
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 ELECTRICAL NETWORKS SPECIFICATION
CONTACT WIRE HARD-DRAWN COPPER 161mm2
MESP 130500-01
Version: 2 Effective from: 2nd May 2018
L1-CHE-SPE-001

6.5 Bend
The wire shall be bent alternately over blocks of a radius equal to that of the wire. The
collector surface and the opposite side of the wire shall be in contact with the blocks.
The sample shall first be bent through 90° with the collector surface in compression. It
shall then be bent twice through 180° in the same plane, that is, through a total of five
bends of 90°.
Complete fracture of the wire shall not occur.

6.6 Electrical resistivity test

The specimens of trolley wire shall each be measured for electrical resistance in
accordance with the method given in IEC 60468 to an accuracy of at least one part in a
thousand at a temperature of not less than 10 °C or more than 30 °C. The length of the
specimen shall be sufficient to give the accuracy required and shall be suitable for the
method of testing used.
The value of the resistance, measured at temperature (T) in degrees Celsius, shall be
corrected to that at 20 °C by multiplying the measured value by a correction factor, (K),
given by:
K = 1/(1+B(T-20))
where B is the constant mass temperature coefficient of resistance of the wire at 20 °C,
which shall be taken as 0.00381 per degree Celsius for hard-drawn copper.

6.7 Retests
Should any one of the test pieces first selected fail to pass the mechanical tests, two
further samples from the same batch shall be selected for testing, one of which shall
be from the wire from which the original test sample was taken, unless that wire has
been withdrawn by the supplier.
Should the test pieces from both these additional samples pass, the batch represented
by the test sample shall be deemed to comply with this specification.
Should the test pieces from either of these additional samples fail, the batch
represented by the test samples shall be deemed not to comply with this specification.

7 Quality Assurance
The Contractor shall meet the requirements of AS/NZS ISO 9001 Quality Management
Systems – Requirements.

8 Warranty
The Contractor shall provide a “Certificate of Conformance” together with a full “Test
Report” as stipulated in Clause 6 Production Test Requirements (Mechanical and
Electrical Resistivity tests) for each drum.

Approving Manager: Head of Engineering Electrical Approval Date: 02/05/2018 Next Review Date: 02/05/2021
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 ELECTRICAL NETWORKS SPECIFICATION
CONTACT WIRE HARD-DRAWN COPPER 161mm2
MESP 130500-01
Version: 2 Effective from: 2nd May 2018
L1-CHE-SPE-001

9 Packing
5.
6.
7.
8.
9.
9.1 The contact wire shall be wound without twists, or kinks, on drums of approved
design and of sufficient size to prevent sharp bends and shall be properly protected
against damage in transit.
9.2 Typically approved design is wooden drums lined with sisal-craft in general
accordance with AS 2857 and the following Metro Trains Melbourne required
dimensions:
Barrel diameter 800 mm minimum
Overall diameter 1,300 mm maximum
Overall width 800 mm maximum
A mild steel reinforcing plate 400 mm square by 6.4 mm thick shall be bolted to the
middle of each side of the drum with a minimum of 6-bolts. An 83 mm square hole shall
be provided in the drum and reinforcing plates to take a 76 mm spindle.
The inner end of the conductor shall be passed through the drum flange to the outside
and stapled securely. The outer end of the conductor shall be secured to the inside of
the drum flange with staples and bent back on itself to prevent it from working loose.
9.3 Metro Trains Melbourne shall specify the length of the conductor on each drum. This
shall be either 1,077 m or 1,350 m. However, there may be a requirement to order
special lengths in the range 1,000 m to 1,700 m.
9.4 The following information shall be legibly and indelibly marked on the flange of the
drums or a label securely attached thereto:
(i) Supplier’s name
(ii) Supplier’s drum serial number
(iii) The conductor material and size (contact wire, hard-drawn copper, 161 mm²)
(iv) Length of conductor
(v) Gross mass of conductor and drum
(vi) Handling or lifting instructions. The preferred method being by means of a
spindle through the spindle holes and a spreader to prevent damage to the
flanges
(vii) An arrow with the words 'ROLL THIS WAY' to indicate the direction in which the
drum should be rolled on the flanges
(viii) The Metro Trains Melbourne contract number and specification number
9.5 Alternative equivalent or superior packing system may be submitted to Metro Trains
Melbourne for consideration.

Approving Manager: Head of Engineering Electrical Approval Date: 02/05/2018 Next Review Date: 02/05/2021
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 ELECTRICAL NETWORKS SPECIFICATION
CONTACT WIRE HARD-DRAWN COPPER 161mm2
MESP 130500-01
Version: 2 Effective from: 2nd May 2018
L1-CHE-SPE-001

10 Appendices
Appendix A: Conductor characteristics (informative information)

Appendix A: Conductor characteristics (informative information)

This appendix does not form part of the specification but is included to provide a convenient
source of conductor parameters associated with the 161 mm² hard drawn copper contact
wire used on Melbourne’s metropolitan network.
Table of conductor particulars
Properties Units
Physical characteristics
Conductor to material reference - Hard drawn copper. Solid in
D3214/8 accordance with this specification
and drawing D3228
Density kg/m3 8890
Elastic modulus MPa 1.23 x 105
Diameter mm 15
Area mm² 161
Weight N/m 14.1
Ultimate tensile stress MPa 325
Calculated Breaking Load (CBL) kN 52.3 (325 UTS)
Coefficient of linear expansion /°C 1.7 x 10-5

Electrical characteristics
Resistivity Ohm-m 17.77 x 10-6

Installed properties
Solar radiation, max W/m² 1000
Emissivity coefficient - 0.3 bright, 1.0 black conductors
Solar absorption coefficient - 0.6 bright, 1.0 black conductors
Wind load, operational (28m/s N/m 7.26
wind)
Wind load, non-operational (41m/s) N/m 15.57
Conductor wear at 10mm gauge % 32
Conductor wear at 9mm gauge % 41
Normal conductor tension kN 15 kN mainline fully weight
regulated
11.2 kN fixed catenary areas,
stabling and crossovers

Approving Manager: Head of Engineering Electrical Approval Date: 02/05/2018 Next Review Date: 02/05/2021
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