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M.B.C College of Engg & Tech Dept. of Electrical & Electronics Engineering Peermade
M.B.C College of Engg & Tech Dept. of Electrical & Electronics Engineering Peermade
ABSTRACT
A new Aluminum alloy conductor having higher conductivity has been developed. By using
these special alloy conductors, electric utility can achieve significant saving in both
transmission and distribution lines. AL-59 alloy conductors are manufactured from Al-Mg-Si
(aluminum-magnesium-silica) rods. The conductor comprises of an inner core and
concentrically arranged strands forming the inner and outer layers of the conductor. ACSR
conductors are limited by a maximum current carrying capacity of 838 amperes. The material
of construction of AL-59 alloy conductors overcome this limitation enabling AL-59 alloy
conductors to transfer up to 1307 amperes of current and evacuate up to 1405 mw of power
(56 per cent higher than ACSR Conductors). Additionally, AL-59 alloy conductors have 9
per cent better 'strength to weight ratio' and 8 per cent lower sag compared with ACSR
conductors which enables effective optimization of tower designs and future proofing of the
grid. In view of development of new power transmission and distribution grids by global
power incumbents, AL-59 alloy conductors would have a special significance while
designing transmission line networks, as the properties of these conductors enable superior
power evacuation while optimizing the cost of the entire grid.
M.B.C COLLEGE OF ENGG & TECH DEPT. OF ELECTRICAL & ELECTRONICS ENGINEERING
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PEERMADE
AL 59 ALLOY CONDUCTOR SEMINAR REPORT-10
INTRODUCTION
The categories of conventional type of Aluminium and Aluminium alloy overhead
conductors available globally are:
Homogeneous Conductors
∗ AAC – All Aluminium Conductors
∗ AAAC – All Aluminium Alloy Conductors
∗ Non – Homogeneous Conductors
∗ ACSR – Aluminium Conductor Steel Reinforced
∗ AACSR-Aluminium Alloy Conductor Steel Reinforced
∗ ACAR – Aluminium Conductor Alloy Reinforced
For several years, distribution and transmission lines have been designed using aluminium
conductors steel reinforced (ACSR) or in some countries all aluminium alloy conductors
(AAAC). Both types normally have a conductivity calculated on the total area of 53-54%
copper (IACS). Since the mid-1970s the cost of producing electric energy has grown rapidly,
leading to an increase in the cost of losses. An attempt to find new conductor material
producing fewer losses in the network was started in Sweden at the beginning of the 1970s
and led in 1979 to the release of a new conductor standard called Al-59, where “59” stands
for its conductivity (IACS). Aluminium Conductors (i) All Aluminium Conducts (AAC) (ii)
All Alloy Aluminium Conductors (AAAC), and (iii) Aluminium Conductors Steel
Reinforced (ACSR) are used in Transmission and Distribution system to carry the generated
electrical energy from generating station to end user. The Electrical energy is normally
generated at the power stations far away from the urban areas where the consumers are
located. There is a large network of conductors between the generating stations and the
consumer. The network is called the Transmission and Distribution system. The
Transmission system is to deliver bulk power from power stations to the load centres and
large industrial consumers beyond the economical service range of the regular primary
distribution lines where as distribution system is to deliver power from power sector or
substations to the various consumers. This transmission and distribution system can employ
either overhead system or underground system. Transmission of power, overhead system
mainly due to low cost and some other advantages ACSR generally used or transmission line
and AAC and AAAC conductors for distribution of power carry out mostly the high voltage
M.B.C COLLEGE OF ENGG & TECH DEPT. OF ELECTRICAL & ELECTRONICS ENGINEERING
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PEERMADE
AL 59 ALLOY CONDUCTOR SEMINAR REPORT-10
transmission. For transmission and distribution of electric power the conductor material used
must have the following characteristics:
Copper, Aluminium, Steel and Steel cored aluminium, galvanised steel conductors are
generally employed for this purpose and preferably stranded in order to increase the
flexibility (Solid wires, except of smaller sizes, are difficult to handle and when employed for
long spans tend to crystallize at the points of support because of the swinging in winds.
Stranded conductors usually have a central wire around which there are successive layers of
6, 12, 18, 24 wires. For 19 layers, the total number of individual wire is 3n (n+1). If the
diameter of each strand is torn diameter of the stranded conductors will be (2n+1) d. In the
process of manufacture adjacent layers are spiraled in opposite direction, so that the layers
are bound together. This method of construction is called as Concentric Lay, out of above
mentioned conducting materials, Aluminium is widely used due to its cheapness and many
others comparative advantages over other conducting materials. However, owing to the fact
that the line or co-efficient of expansion of aluminium is 104 times that of copper, the sag is
greater in aluminium wire, therefore, steel cored Aluminium (ACSR) wire is used to
compensate this property of Aluminium. The steel conductors used are galvanised in order to
prevent rusting and electrolytic corrosion. The AAC/AAAC/ACSR conductors for high
voltage transmission have first replaced the bore copper conductors where copper is scarce
and costly on the other hand EC grade Aluminium is easily available in India and as far as the
electric properties are concerned, aluminium is equally good being lighter in weight and for
same sage span length of the transmission could be increased in comparison to copper.
Keeping in view the simple technology involved AAC/ACSR/AAAC conductors up to 19
strand have been reserved for exclusive production in small scale sector. However,
Aluminium conductors up to 61 strand can be manufactured. Different types of aluminium
conductors manufactured are:
v) Aluminium conductors galvanised steel reinforced for extra high voltage (400 kV or
above) (ACSR)
HISTORY
In 1920’s, within about 20 years of introducing ACSR, France introduced for the first time a
new type of electric al conductor made of an alloy of aluminium with magnesium and silicon
alloy. Other European countries also developed similar material as their conductor material
US also followed the same in 1960’s The electrical conductor made of such alloy had higher
strength than EC grade aluminium of equal size with slight loss in conductivity. Due to the
increased strength the conductors did not require steel reinforced. AAAC thus made its
advent as the most suitable current carrier in transmission and distribution. IEC
recommendation number 208 provides an internationally acceptable standard for AAAC
(Aluminium Alloy Conductors). At the beginning of 70’s AB Electrokopper in Helinsburg
developed an alloy with the trade name DUCTALEX. It has a better conductivity than the
alloys developed by the France but a slightly lower mechanical strength.
This new conductor alloy was laboratory tested at the Swedish State Power Board with
respect to creep, corrosion resistance, self damping and fatigue strength, all tests showed the
same or better properties than the ordinary alloy. Tests were made on actual distribution lines
starting in 1975. As only satisfactory results were obtained the new alloy was installed in 400
KV line. The measurement of sag after five years showed a high degree of agreement with
what was predicted. Concurrent with all trials the Swedish Standardization Committee
worked out and issued the standards SS4240813 for AL-59 wires and SS4240814 for AL-59
conductors.
M.B.C COLLEGE OF ENGG & TECH DEPT. OF ELECTRICAL & ELECTRONICS ENGINEERING
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AL 59 ALLOY CONDUCTOR SEMINAR REPORT-10
The basis for calculation of production capacity has been taken on two shifts per day
basis on 75% efficiency.
The maximum capacity utilization on two shifts basis per day for 300 days a year.
During first year and second year of operations the capacity utilization is 60% and
80% respectively.
The unit is expected to achieve full capacity utilization from the third year onwards.
The salaries and wages, cost of raw materials, utilities, rents, etc. are based on the
prevailing rates. The cost factors may vary with time and location.
Interest on term loan and working capital loan has been taken at the rate of 12% on an
average. This rate may vary depending upon the policy of the financial
institutions/agencies from time to time.
The cost of machinery and equipments refer to a particular make / model and prices
are approximate.
The break-even point percentage indicated is of full capacity utilization.
The project preparation cost etc. whenever required could be considered under pre-
operative expenses.
The essential production machinery and test equipment required for the project have
been indicated. The unit may also utilize common test facilities available at
Electronics Test and Development Centers (ETDCs) and Electronic Regional Test
Laboratories (ERTLs) and Regional Testing Centers (RTCs)
MANUFACURING PROCESSES
The process of manufacturing of Aluminium Alloy Conductors (AAC), Aluminium
Conductor Steel Reinforced (ACSR) and All Aluminium Alloy Conductor (AAAC),
Aluminium 59 etc. involves the following process:
Drawing of aluminium alloy rod of 9.5mm dia into the required size through a set of
gradually reducing sizes of dies in wire drawing machine and wounded up on a spool.
The required number of spools fitted in the tubular stranding machine and stranded in
a wooden drum.
For ACSR and AAAC the alloy rod is drawn into 7.15 mm dia and put in furnace for
heat treatment at a constant temperature at 530oC for 40 minutes.
M.B.C COLLEGE OF ENGG & TECH DEPT. OF ELECTRICAL & ELECTRONICS ENGINEERING
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AL 59 ALLOY CONDUCTOR SEMINAR REPORT-10
After heat treatment the heat treated alloy wire dipped into the cold water in a
quenching tank for 30 to 40 minutes within 6 to 10 seconds of heat treatment.
The quenched alloy wire then dried for 8 to 12 hours.
7.15 mm alloy wire then finally drawn into different sizes in wire drawing machine.
The drawn wire then subjected to ageing at 160oC temperature for 4 hours in furnace
on condition and kept inside furnace for on condition and kept inside furnace for
another 2 to 4 hours in furnace off condition.
After standing the alloy conductors in a 7 stand high speed tubular machines in 61
strand (7+54) multi layer stranding machine.
Stranded wire inspected and tested for resistance, elongation and breaking load before
finally dispatching to customer.
M.B.C COLLEGE OF ENGG & TECH DEPT. OF ELECTRICAL & ELECTRONICS ENGINEERING
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AL 59 ALLOY CONDUCTOR SEMINAR REPORT-10
AL 59 ALLOY CONDUCTOR
AL-59 alloy conductors are manufactured from Al-Mg-Si (aluminum-magnesium-silica)
rods. The conductor comprises of an inner core and concentrically arranged strands forming
the inner and outer layers of the conductor. ACSR conductors are limited by a maximum
M.B.C COLLEGE OF ENGG & TECH DEPT. OF ELECTRICAL & ELECTRONICS ENGINEERING
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PEERMADE
AL 59 ALLOY CONDUCTOR SEMINAR REPORT-10
current carrying capacity of 838 amperes. The material of construction of AL-59 alloy
conductors overcome this limitation enabling AL-59 alloy conductors to transfer up to 1307
amperes of current and evacuate up to 1405 mw of power (56 per cent higher than ACSR
Conductors). Additionally, AL-59 alloy conductors have 9 per cent better 'strength to weight
ratio' and 8 per cent lower sag compared with ACSR conductors which enables effective
optimization of tower designs and future proofing of the grid. In view of development of new
power transmission and distribution grids by global power incumbents, AL-59 alloy
conductors would have a special significance while designing transmission line networks, as
the properties of these conductors enable superior power evacuation while optimizing the cost
of the entire grid.
Chemical composition:
Mark Chemical composition [ % ]
Fe Si Cu Mn Mg Cr Zn B Ti+V Al
AI59
0,40 0,1 0,35 0,01 0,2 0,01 0,05 0,05 0,02 99,2
M.B.C COLLEGE OF ENGG & TECH DEPT. OF ELECTRICAL & ELECTRONICS ENGINEERING
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PEERMADE
AL 59 ALLOY CONDUCTOR SEMINAR REPORT-10
M.B.C COLLEGE OF ENGG & TECH DEPT. OF ELECTRICAL & ELECTRONICS ENGINEERING
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PEERMADE
AL 59 ALLOY CONDUCTOR SEMINAR REPORT-10
Al-59 Alloy Conductors have been used extensively by Swedish Electricity, Swedish
Railways and Norway Electricity.
MATERIAL PROPERTIES
Size of the Conductor AL-59 conductors range from AL-59 31 sq-mm (7/2.38 mm) to AL-
59 910 sq-mm (61/4.36 mm).
Strength of the wire
♥ For diameter less than 3.5 mm: 250 MPA
♥ For diameter less than 4 mm: 240 MPA
♥ For diameter less than 4.5 mm: 230 MPA
Resistivity of the wire
♥ Individual resistivity: 29.30 nJm
♥ Average resistivity: 29.08 nJm
Fig. 4 AL 59 Conductors
Creep of the conductor
Maximum conductor Creep at 23oC at 40 % of rated tensile
strength and 1500 hours are as
Follows
♥ 7 strands: 350 mm/Km
♥ 19 and 37 strands: 400 mm/Km
♥ 61 strands: 450 mm/Km
M.B.C COLLEGE OF ENGG & TECH DEPT. OF ELECTRICAL & ELECTRONICS ENGINEERING
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AL 59 ALLOY CONDUCTOR SEMINAR REPORT-10
The comparison for transmission as well as for the distribution is as detailed below:
M.B.C COLLEGE OF ENGG & TECH DEPT. OF ELECTRICAL & ELECTRONICS ENGINEERING
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AL 59 ALLOY CONDUCTOR SEMINAR REPORT-10
M.B.C COLLEGE OF ENGG & TECH DEPT. OF ELECTRICAL & ELECTRONICS ENGINEERING
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AL 59 ALLOY CONDUCTOR SEMINAR REPORT-10
M.B.C COLLEGE OF ENGG & TECH DEPT. OF ELECTRICAL & ELECTRONICS ENGINEERING
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AL 59 ALLOY CONDUCTOR SEMINAR REPORT-10
Comparison of AAAC 61/4.26, ACSR Bersimis and AL-59 910 sq.mm conductors
M.B.C COLLEGE OF ENGG & TECH DEPT. OF ELECTRICAL & ELECTRONICS ENGINEERING
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AL 59 ALLOY CONDUCTOR SEMINAR REPORT-10
Even though strength of the AL-59 conductor is less compared to conventional AAAC, AL- 9
is strung at the same tension as like conventional AAAC. The Important factor for choosing
tension from the vibrating point of view is tension divided by the conductor mass. This value
is independent of Ultimate tensile strength
M.B.C COLLEGE OF ENGG & TECH DEPT. OF ELECTRICAL & ELECTRONICS ENGINEERING
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AL 59 ALLOY CONDUCTOR SEMINAR REPORT-10
M.B.C COLLEGE OF ENGG & TECH DEPT. OF ELECTRICAL & ELECTRONICS ENGINEERING
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AL 59 ALLOY CONDUCTOR SEMINAR REPORT-10
CONCLUSION
Power for all by the year 2012 is the vision of the Ministry of Power, Government of India.
2012. Such an integrated grid is envisaged to evacuate additional 1, 00,000 MW by the year
2012 and carry 60% of the power generated in the country. The existing inter-regional power
reports that the global market for power transmission conductors was valued at about
US$12.3 Billion in 2006 and has a CAGR of 7% from 2004 through 2006. ABS Research
also anticipates a stable demand growth in the global market from 2007 through 2010 at a
CAGR of about 7%. In view of development of new power transmission and distribution
grids by global power incumbents, Al-59 Alloy Conductors would have a special significance
while designing transmission line networks, as the properties of these conductors enable
superior power evacuation while optimizing the cost of the entire grid.
M.B.C COLLEGE OF ENGG & TECH DEPT. OF ELECTRICAL & ELECTRONICS ENGINEERING
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AL 59 ALLOY CONDUCTOR SEMINAR REPORT-10
REFERANCES
-www.sterlitetechnologies.com
New range of special alloy conductors – Advantages over ACSR & AAAC
conductors
Author G L Prasad
www.midalcable.com
M.B.C COLLEGE OF ENGG & TECH DEPT. OF ELECTRICAL & ELECTRONICS ENGINEERING
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