Engineering Specification Electrical Networks TECHNICAL SPECIFICATION FOR CATENARY WIRE HARD-DRAWN COPPER 37/2.5 181mm 2 Version: 3 Issued: February 2017 Owner: Engineering Division Approved By: Andrew Russack Head of Engineering (Electrical) PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION
Approval Amendment Record Approval Date Version Description 23/01/2015 1 Initial issue 24/02/2016 2 Reference to joints has been removed. Joints are no longer permissible. Updated DC resistance in table. 27/02/2017 3 Inclusion of item 6g to align with AS 1746-1991. Reference to standard AS 2505.6:2002 included. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 2 of 7
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. Lay... 6 9. Dimensions... 6 10. Production Test Requirements... 6 11. Quality Assurance... 6 12. Warranty... 6 13. Packing... 6 14. Delivery... 7 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 3 of 7
1. Purpose This document details the specification of 181 mm² hard-drawn copper Catenary Wire 2. Scope The scope comprises the manufacture, testing, supply and delivery of 181 mm² hard-drawn copper Catenary Wire in accordance with this specification and to the entire satisfaction of Metro Trains Melbourne. 3. Abbreviation GPa Kg Km kn mm MPa Gigapascal Kilogram Kilometre Kilonewton Millimetre Megapascal 4. Definitions Lay Ratio The ratio of the lay length to the external diameter of the corresponding layer of wires 5. References & Legislations AS 1391-2007 AS 1746-1991 AS 2193-2005 AS 2505.6:2002 AS 2738:2000 AS 3822-2002 AS/NZS 1574-1996 AS/NZS 2857:1996 AS/NZS ISO 9001 Metallic Materials Tensile Testing at Ambient Temperature Conductors - Bare Overhead - Hard-Drawn Copper Calibration and Classification of Force Measuring Systems Metallic Materials - Wire - Wrapping Test Copper and Copper Alloys - Compositions and Designations of Refinery Products, Wrought Products, Ingots and Castings Test Methods for Bare Overhead Conductors Copper and Copper Alloys - Wire for Electrical Purposes Timber Drums for Insulated Electric Cables and Bare Conductors Quality Management Systems - Requirements. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 4 of 7
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 0.017 77 µω.m (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 1574-1996. d. The wire shall be clean, smooth and free from all defects. e. There shall be no joints in the wire. f. The wire density at 20 C shall be 8,890 kg/m³ plus or minus 3%. g. All strands shall be subjected to a wrapping test in accordance with AS 2505.6:2002. Each specimen shall be wrapped around a wire of its own diameter to form a close helix of eight turns. Six turns shall than be unwrapped and again closely re-wrapped. The wrapping rate shall not exceed 60 turns per minute. The wire shall show no signs of cracks to the visible eye or breaks. 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: 36.34 o Mass: 37.68 Resistance: 0.027 52 Strand Dia. (mm) Cross-sectional area (mm²) Mass/km (kg) Calculated breaking load (kn) DC resistance/km @ 20 C (ohms) 2.5 (nom) 181.6 1644 70.28 0.099 6 2.475 (-1%) 178 1611 68.88 0.101 6 The Calculated Break Load of the conductor is 90% 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 108GPa. 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. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 5 of 7
8. Lay Lay ratio and direction of the three layers shall be: 6-wire layer: 10 min, 17 max. Right-hand lay 12-wire layer: 10 min, 16 max. Left-hand lay 18-wire layer. 10 min, 16 max. Right-hand lay 9. Dimensions Wire size and tolerances shall be in accordance with AS 1746-1991. For a 37/2.5 nominal conductor of 181mm² nominal cross-sectional area the overall wire diameter shall be 17.5mm +/- 1%. 10. 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, AS 2505.6:2002 and AS 3822. 11. Quality Assurance The Supplier should meet the requirements of AS/NZS ISO 9001. 12. Warranty The Supplier shall provide a Certificate of Conformance together with a full test report as stipulated in Production Test Requirements. 13. 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 600mm minimum o Overall diameter 1200mm maximum o Overall width 920mm 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. 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. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 6 of 7
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) (ii) Supplier s name Supplier s drum serial number (iii) The conductor material and size (Hard-drawn copper, catenary wire 37/2.5, 181mm2) (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, order number and specification number e) Alternative equivalent or superior packing system may be submitted to Metro Trains Melbourne for consideration. 14. 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. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 7 of 7