TECHNICAL SPECIFICATION FOR. CONTACT WIRE HARD-DRAWN COPPER 161mm2

Transcription

1 Engineering Specification Electrical TECHNICAL SPECIFICATION FOR CONTACT WIRE HARD-DRAWN COPPER 161mm2 Version: 2 Issued: May 2018 Owner: Engineering Approved by: Andrew Russack, Head of Engineering Electrical

2 Approval Amendment record Approval Date Version Description Initial issue under MTM. This document replaces Mainco Specification MESP 0002 Revision A. Rebranded & 19/09/ reformatted to reflect MTM. Reference to EN removed (does not specify the characteristics of 161mm 2 copper alloy wire). 02/05/ Normal conductor tension in Appendix A corrected from 20kN to 15kN Reference to 310 UTS removed from Appendix A. Minimum UTS remains unchanged at 325 MPa. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 2 of 8

3 Table of Contents 1 Scope of work General information Standards Material Dimensions Production test requirements Mechanical tests Tensile Elongation Torsion Bend Electrical resistivity test Retests Quality Assurance Warranty Packing Appendices... 8 Appendix A: Conductor characteristics (informative information)... 8 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 3 of 8

4 1 Scope of work The scope comprises the manufacture, testing, supply and delivery of 161 mm² harddrawn 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 AS 2193 AS/NZS 2857 AS 1391 AS/NZS ISO 9001 IEC Copper and copper alloys Compositions and designations of refinery products, wrought products, ingots and castings 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 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 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 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%. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 4 of 8

5 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 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 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 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. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 5 of 8

6 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 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 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. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 6 of 8

7 9 Packing 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 Overall diameter Overall width 800 mm minimum 1,300 mm maximum 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) (ii) Supplier s name Supplier s drum serial number (iii) The conductor material and size (contact wire, hard-drawn copper, 161 mm²) (iv) (v) (vi) (vii) (viii) Length of conductor Gross mass of conductor and drum 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 An arrow with the words 'ROLL THIS WAY' to indicate the direction in which the drum should be rolled on the flanges 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. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 7 of 8

8 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 Physical characteristics Conductor to material reference D3214/8 Units - Hard drawn copper. Solid in accordance with this specification and drawing D3228 Density kg/m Elastic modulus MPa 1.23 x 10 5 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 x 10-6 Installed properties Solar radiation, max W/m² 1000 Emissivity coefficient bright, 1.0 black conductors Solar absorption coefficient bright, 1.0 black conductors Wind load, operational (28m/s N/m 7.26 wind) Wind load, non-operational (41m/s) N/m 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 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 8 of 8