Engineering Specification Electrical Networks MESP 130400-02 TECHNICAL SPECIFICATION FOR FLEXIBLE DROPPER WIRE TIN-BEARING COPPER Version: 1 Issued: November 2015 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 09/11/2015 1 Initial issue 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... 5 9. Dimensions... 5 10. Production Test Requirements... 6 11. Quality Assurance... 6 12. Warranty... 6 13. Packing... 6 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 9.6 mm² tin-bearing copper dropper wire for use in the Melbourne Metropolitan Overhead Wiring System. 2. Scope The scope comprises the manufacture, testing and supply of 9.6 mm² tin-bearing copper dropper wire. 3. Abbreviation d Diameter of strand in millimeters 4. Definitions Lay Ratio Ovality The ratio of the lay length to the external diameter of the corresponding layer of wires The difference between the maximum and minimum diameter measurements taken in the same cross-section 5. References & Legislations AS 1391:2007 Metallic Materials Tensile Testing at Ambient Temperature AS 2193:2005 AS 2738:2000 AS 3822:2002 AS/NZS 1574:1996 AS/NZS 2857:1996 AS/NZS ISO 9001 Calibration and Classification of Force Measuring Systems 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 149 (Tin-bearing copper). b. The maximum resistivity at 20 C is 0.023 6 µω.m (equivalent to a conductivity of 73% IACS). c. The minimum ultimate tensile strength is 600 MPa for the individual strands of the hard-drawn copper wire. Although the diameter of the wire is less than 0.5 mm, the ultimate tensile strength is given by 620-33.3d as per alloy designation 149 in AS 1574:1996. d. The Calculated Break Load of the conductor is 90% of the sum of the strengths of the individual strands before stranding e. The wire shall be clean, smooth and free from all defects f. There shall be no joints in the wire. g. The wire density at 20 C shall be 8,890 kg/m³ plus or minus 3%. h. The coefficient of linear expansion is taken as 17x10-6 per C. i. The modulus of elasticity is taken as 123 GPa. This value is taken after the initial stretch of the wire following construction. 7. Conductor Characteristics Strand Dia. (mm) Cross-sectional area (mm²) Mass/km (kg) Calculated breaking load (kn) DC resistance/km @ 20 C (ohms) 0.5 (nom) 9.6 86.8 5.2 2.45 0.49 (-1%) 9.24 83.7 5.0 2.59 8. Lay Lay ratio and direction of the layers shall be: Primary bunch: 27.6 mm nom Left-hand lay 6-wire layer: 49 mm min, 49.8 mm max Right-hand lay 9. Dimensions Wire size and tolerances shall be in accordance with AS 1574:1996. For a 7/7/0.5 nominal conductor of 9.6 mm² nominal cross-sectional area, the overall wire diameter shall be 4.5 mm +/- 1%. Single wire ovality shall be within 1% of nominal diameter (0.5 mm). PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 5 of 7
10. Production Test Requirements For the purposes of this specification the metallurgical tests shall be in accordance with AS/NZS 1574:1996. Mechanical and electrical tests shall be in accordance with AS 1574:1996 and AS 3822:2002. 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 dropper 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 2857:1996 and the following Metro Trains Melbourne required dimensions: o Barrel diameter 200 mm minimum o Overall diameter 400 mm maximum o Overall width 250 mm maximum o Round shaft hole diameter 55 mm 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) (ii) Supplier s name Supplier s drum serial number (iii) The conductor material and size (Tin-bearing copper, dropper wire 7/7/0.5, 9.6mm 2 ) (iv) (v) Length of conductor Gross mass of conductor and drum PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 6 of 7
(vi) (vii) (viii) 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. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 7 of 7