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Engineering Specification Electrical Networks MESP 050100-03 TECHNICAL SPECIFICATION FOR TRANSMISSION WIRE HARD-DRAWN COPPER 7/2.5 35mm Owner:

Engineering Specification Electrical Networks

MESP 050100-03 TECHNICAL SPECIFICATION FOR

TRANSMISSION WIRE HARD-DRAWN COPPER 7/2.5 35mm 2

Owner: Engineering Division

Approved By:

Paul O’Halloran

Chief Engineer

Version:

1

Issued:

February 2015

Engineering Specification Electrical Networks MESP 050100-03 TECHNICAL SPECIFICATION FOR TRANSMISSION WIRE HARD-DRAWN COPPER 7/2.5 35mm Owner:

PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION

ELECTRICAL NETWORKS SPECIFICATION

ELECTRICAL NETWORKS SPECIFICATION

TRANSMISSION WIRE HARD-DRAWN COPPER 7/2.5 35mm 2

MESP 050100-03

 

Effective from: 10 th February 2015

L1-CHE-SPE-018

Version: 1

Approval

ELECTRICAL NETWORKS SPECIFICATION TRANSMISSION WIRE HARD-DRAWN COPPER 7/2.5 35mm MESP 050100-03 Effective from: 10 February 2015

Amendment Record

Approval Date

Version

Description

10/02/2015

1

New document

Approving Manager: Chief Engineer

Approval Date: 10/02/2015

Next Review Date: 10/02/2018

PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION

Page 2 of 7

ELECTRICAL NETWORKS SPECIFICATION

ELECTRICAL NETWORKS SPECIFICATION

TRANSMISSION WIRE HARD-DRAWN COPPER 7/2.5 35mm 2

MESP 050100-03

 

Effective from: 10 th February 2015

L1-CHE-SPE-018

Version: 1

Table of Contents

  • 1. Purpose

..........................................................................................................................

4

  • 2. Scope ..............................................................................................................................

4

  • 3. Abbreviation ..................................................................................................................

4

  • 4. Definitions

.....................................................................................................................

4

  • 5. References & Legislations

.........................................................................................

4

  • 6. Material ...........................................................................................................................

5

  • 7. Conductor Characteristics

.........................................................................................

5

8.

9.

Lay

...................................................................................................................................

6

Dimensions

...................................................................................................................

6

  • 10. Pre-production Test Requirements

..........................................................................

6

  • 11. Production Test Requirements

.................................................................................

6

  • 12. Quality Assurance

.......................................................................................................

6

13.

Warranty

.........................................................................................................................

6

14.

15.

Packing

..........................................................................................................................

6

Delivery

..........................................................................................................................

7

Approving Manager: Chief Engineer

Approval Date: 10/02/2015

Next Review Date: 10/02/2018

PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION

Page 3 of 7

ELECTRICAL NETWORKS SPECIFICATION

ELECTRICAL NETWORKS SPECIFICATION

TRANSMISSION WIRE HARD-DRAWN COPPER 7/2.5 35mm 2

MESP 050100-03

 

Effective from: 10 th February 2015

L1-CHE-SPE-018

Version: 1

  • 1. Purpose This document details the specification of 35 mm² hard-drawn copper Transmission Wire

  • 2. Scope The scope comprises the manufacture, testing, supply and delivery of 35 mm² hard-drawn copper Transmission Wire in accordance with this specification and to the entire satisfaction of Metro Trains Melbourne.

  • 3. Abbreviation

GPa

Gigapascal

Kg

Kilogram

Km

Kilometre

kN

Kilonewton

mm

Millimetre

MPa

Megapascal

  • 4. Definitions

Lay Ratio

The ratio

of

the

lay

length

to

the

external

diameter

of

the

corresponding layer of wires

 

Right-hand Lay

When the slope of the wires is in the direction of the central part of the letter Z when the conductor is held vertically

  • 5. References & Legislations

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 1746-1991 AS 3822 AS 2193 AS/NZS 2857 AS 1391 AS/NZS ISO 9001

Conductors - Bare Overhead - Hard-Drawn Copper Test Methods for Bare Overhead Conductors Calibration and Classification of Force Measuring Systems Timber Drums for Insulated Electric Cables and Bare Conductors Metallic Materials Tensile Testing at Ambient Temperature Quality Management Systems - Requirements.

Approving Manager: Chief Engineer

Approval Date: 10/02/2015

Next Review Date: 10/02/2018

PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION

Page 4 of 7

ELECTRICAL NETWORKS SPECIFICATION

ELECTRICAL NETWORKS SPECIFICATION

TRANSMISSION WIRE HARD-DRAWN COPPER 7/2.5 35mm 2

MESP 050100-03

 

Effective from: 10 th February 2015

L1-CHE-SPE-018

Version: 1

  • 6. Material

    • a. The chemical composition of the material used for the solid conductor shall conform to AS 2738 alloy designation C11000 (Electrolytic tough pitch copper).

    • b. The maximum resistivity at 20°C is 0.01777 micro ohm/metre (equivalent to a conductivity of 97% IACS).

    • c. The minimum Ultimate Tensile Strength is 430MPa for the individual strands of the hard- drawn copper wire. The Ultimate Tensile Strength is given by 480-20d as per alloy designation C11000 in AS 1574.

    • d. The wire shall be clean, smooth and free from all defects

    • e. Joints shall be made in the soft rolled rod before drawing by cold pressure butt-welding, resistance butt-welding or resistance brazing. The wire at the joints shall comply with the requirements of Clauses b and c of this section. The minimum distance between two such joints in the conductor shall be 15m.

    • f. The wire density at 20°C shall be 8,890 kg/m³ plus or minus 3%.

  • 7. Conductor Characteristics The lay ratio affects the area, mass and resistance of conductors composed of stranded wires. The following stranding constants are multiplied with the corresponding property of a single strand to give the overall characteristic:

  • Stranding constants:

     

    o

    Area: 6.942

    o

    Mass: 7.05

    Resistance: 0.144

    Strand Dia.

    Cross-sectional

    Mass/km (kg)

    Calculated breaking

    DC resistance/km @

    (mm)

    area (mm²)

    load (kN)

    20°C (ohms)

    2.5 (nom)

    • 34.36 305

     
    • 13.59 0.517

     

    2.48 (-1%)

    • 33.81 300

     
    • 13.37 0.525

     

    The Calculated Break Load of the conductor is 92% of the sum of the strengths of the individual strands before stranding. This is based on a minimum Ultimate Tensile Strength of 480-20d MPa where ‘d’ is the diameter of the strand in millimeters.

    Modulus of elasticity may be taken as 112GPa. This value is obtained after the initial stretch of the wire following construction.

    Coefficient of linear expansion may be taken as 17x10 -6 per °C.

    Approving Manager: Chief Engineer

    Approval Date: 10/02/2015

    Next Review Date: 10/02/2018

    PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION

    Page 5 of 7

    ELECTRICAL NETWORKS SPECIFICATION

    ELECTRICAL NETWORKS SPECIFICATION

    TRANSMISSION WIRE HARD-DRAWN COPPER 7/2.5 35mm 2

    MESP 050100-03

     

    Effective from: 10 th February 2015

    L1-CHE-SPE-018

    Version: 1

    • 8. Lay Lay ratio and direction of the outer layer shall be: 6-wire layer:

    13 min, 17 max.

    • 9. Dimensions

    Right-hand lay

    Wire size and tolerances shall be in accordance with AS 1746-1991. For a 7/2.5 nominal conductor of 35mm² nominal cross-sectional area the overall wire diameter shall be 7.5mm +/- 1%.

    • 10. Pre-production Test Requirements Mechanical, resistivity and suitable metallurgical tests shall be performed on samples of wire joints produced using identical parameters to final production condition.

    • 11. Production Test Requirements For the purposes of this specification the metallurgical tests shall be in accordance with AS/NZS 1574. Mechanical and electrical tests shall be in accordance with AS 1746-1991 and AS 3822.

    • 12. Quality Assurance The Supplier should meet the requirements of AS/NZS ISO 9001.

    • 13. Warranty The Supplier shall provide a Certificate of Conformance’ together with a full test report as stipulated in Production Test Requirements.

    • 14. Packing

      • a) The transmission 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.

      • b) Typically approved design is wooden drums lined

    with sisal-craft in general

    accordance with AS 2857 and the following Metro Trains Melbourne required dimensions:

    o

    Barrel diameter

    500mm minimum

    o

    Overall diameter

    1000mm maximum

    o

    Overall width

    650mm maximum

    A mild steel reinforcing plate 400mm2 by 6.4mm thick shall be bolted to the middle of each side of the drum with a minimum of 6 bolts. An 83mm square hole shall be provided in the drum and reinforcing plates to take a 76mm spindle.

    Approving Manager: Chief Engineer

    Approval Date: 10/02/2015

    Next Review Date: 10/02/2018

    PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION

    Page 6 of 7

    ELECTRICAL NETWORKS SPECIFICATION

    ELECTRICAL NETWORKS SPECIFICATION

    TRANSMISSION WIRE HARD-DRAWN COPPER 7/2.5 35mm 2

    MESP 050100-03

     

    Effective from: 10 th February 2015

    L1-CHE-SPE-018

    Version: 1

    The free ends of the wire shall be suitably treated to prevent de-stranding. 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.

    • c) Metro Trains Melbourne shall specify the length of the conductor on each drum.

    • d) 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 (Hard-drawn copper, transmission wire 7/2.5, 35mm 2 )

    (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, order number and specification number

    • e) Alternative equivalent or superior packing system may be submitted to Metro Trains Melbourne for consideration.

    15.

    Delivery

    Transmission wires shall be delivered free into Metro Trains Melbourne Central Store. The Central Store is located at E-Gate, Footscray Road, West Melbourne, Victoria 3051 and delivery shall take place during business hours Monday to Friday (except Public Holidays) from 0800 till 1530. Metro Trains Melbourne shall be notified of any delivery 5-working days prior to delivery.

    Approving Manager: Chief Engineer

    Approval Date: 10/02/2015

    Next Review Date: 10/02/2018

    PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION

    Page 7 of 7