International Conference on Condition Monitoring, Diagnosis and Maintenance

th
CMDM 2021 (6 edition)
October 11th – 13th 2021
Radisson Blu Hotel Bucharest, Romania
111

WHAT ANNEALING IS AND HOW IT DEGRADES THE MECHANICAL CHARACTERISTICS OF

THE ALUMINUM STRANDS? SOLUTIONS!

G. A. FLOREA1, M. MOCANU1, A. SERBAN1, E. MATEESCU2, L. LIPAN3

Power& Lighting Tehnorob S. A.1, Gopa Intec S. A.2, University Politehnica Bucharest3
ROMANIA

SUMMARY
The aluminum strand annealing is a metallurgical process of recrystallization where an applied temperature softens the
hardened aluminum, resulting a loss of the strength. The annealing of the aluminum 1350-H19 starts at 93°C and its
intensity depends on the magnitude of the temperature and the time of the application. At lower temperatures (below
93°C), the effect is negligible, but at higher temperatures the effect becomes significant and occurs quickly.
The conductor strength is reduced gradually, but the reduction due to the conductor aging by the aluminum strand
annealing is accumulated over time. The strength loss due to the annealing of the aluminum wires is a temperature and
time dependent phenomenon. To determine the probable loss of strength over the expected life of the conductor is to
predict the time the conductor will experience temperatures that will occasion the annealing. The heating due to the
short circuits has to be considered, too. The total time of the faults is generally very small, but the temperature of the
conductors during the short circuits becomes much higher than usual.
The temperatures are changing from the surface to the core of the conductor, and even changing circumferentially.
Certainly, the conductor core and surface temperatures are also changing along the span.
To avoid the risk of the aluminum strand annealing two steps have to be taken into account: the first to establish the
right temperature difference between the outer strand and the inner strand and the second, monitoring the line conductor
outer strand highest temperature, keeping it under control to not exceed the critical temperature of annealing starting.

KEYWORDS
Stranded Conductors, Aluminum Strands, Annealing, Power Transmission – Overhead Line, Tensile Strength,
Monitoring the Conductor Temperatures

georgeflorea@tehnorob.ro
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1. INTRODUCTION

The aluminum strand annealing is a metallurgical process of recrystallization where an applied temperature softens the
hardened aluminum, resulting a loss of the strength, Usually, the wires used in the ACSR and AAC conductors are the
aluminum 1350-H19 wires. About 70% of the strength of 1350-H19 aluminum is a result of hardening. The annealing
of the aluminum 1350-H19 starts at 93°C and its intensity depends on the magnitude of the temperature and the time of
the application. An important body of work concerning the aluminum strand annealing has been published by Cigré and
IEEE on the topic of aluminum conductor strands, the main ones being the “Thermal behaviour of overhead
conductors” in the CIGRE technical brochure 207 [B1, B2] and the IEEE Standard 1283- 2004 As “IEEE Guide for
determining the effects of high temperature operation on conductors, connectors and accessories” [B3], but not to forget
the previous works (1965-1992) leading to the CIGRE technical brochure ELT-144-3 [B0]. These are covering the
thermal behaviour of overhead conductors at low current densities (<1.5 A/mm2) and low temperatures (<100ºC)
without to consider variations in weather conditions. At lower temperatures (below 93°C), the effect is negligible, but at
higher temperatures the effect becomes significant and occurs quickly [ B3, B4, B5].
A newer technical brochure of CIGRE was finalized by WG B2.43 in 2014, The TB no. 601 “GUIDE FOR THERMAL
RATING CALCULATIONS OF OVERHEAD LINES”, to take into consideration the conductors for higher currents
and higher temperatures.

2. TENSILE STRENGTH REDUCTION DUE TO THE ALUMINUM STRAND

ANNEALING

The rated tensile strength of a stranded conductor is obtained as the sum of the strengths of the individual wires. In the
case of the all-aluminum conductor (AAC) the loss of strength of the conductor due to annealing is directly
proportional to the degradation of the aluminum, all the wires being of aluminum only. The aluminum conductor,
alloy reinforced conductors (ACAR) content 1350-H19 wires and aluminum-alloy 6201-T81 wires, the both types can
be affected by the annealing, if their temperature exceeds 93°C, the conductor loss of strength being directly
proportional to the degradation of the aluminum and aluminum-alloy [B6].
The ACSR conductors, the aluminum steel reinforced conductors have a core of steel wires overlaid by one or more
layers of aluminum 1350-H19 wires. There is not to meet any annealing of the steel wires at the temperatures the
ACSR conductors are operating, even in the emergency conditions, if the temperature is lower than 200ºC [B3] or
225ºC [B1, B7, B8]. The loss of strength of the ACSR conductor results as a function of the loss of strength of the
aluminum wires compared to the rated strength of both the aluminum and steel wires. Generally, the ACSR tensile
stress derives about half of it from the steel wires and half from the aluminum wires. So, the aluminum strand
annealing, if it occurs, will lead to a lower loss of the strength of the full conductor compared to the AAC or ACAR
conductors.
The conductor strength is reduced gradually, but the reduction due to the conductor aging by the aluminum strand
annealing is accumulated over time. The strength loss due to the annealing of the aluminum wires is a temperature and
time dependent phenomenon. To determine the probable loss of strength over the expected life of the conductor is to
predict the time the conductor will experience temperatures that will occasion the annealing. The heating due to the
short circuits has to be considered, too. The total time of the faults is generally very small, but the temperature of the
conductors during the short circuits becomes much higher than usual.
The thinner wires loose tensile strength more rapidly than the thicker wires, the colder work exerted to the thinner
wires being higher [B9].
This loss in strength under heavy mechanical loads (wind, ice) can permanently shift a large percentage of the tensile
load from the aluminum strands onto the steel core. This redistribution of load causes extra conductor elongation,
hence, greater sags than originally designed. [B3].

2.1. Tensile strength reduction because of the annealing during the normal operation conditions
(steady- state)

The tensile strength reduction of aluminum wires at temperatures of less than 90ºC is considered negligible. At 100ºC,
the tensile strength of the wire is reduced by 10% after 5000 hours and at 125ºC, the tensile strength is reduced 10%
after 250 hours [B10].
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Fig. 1 Remaining stress of aluminum strands after annealing

2.2. Tensile strength reduction due to the annealing during the short circuit conditions

The short circuits result in extremely large currents from the fault initiating time until the interruption by the protective
devices, the fault duration, nowadays, is usually from 3 to maximum 20 cycles, in the case of the transmission lines.
The heating is more rapid than the cooling, the conductor temperature increasing quickly. Anyhow, for the ACSR, a
maximum temperature to avoid the conductor melting has to be established, an upper limit of 645ºC degrees being met
for in [B10], but 200ºC in [B2].
The remaining strength of four different conductors were determined after applying a short- circuit current of 5 to 30
kA for a period of 1 second [B11], in Fig. 2.

Fig. 2. Remaining strength after a short circuit of various conductors for an average span of 400 m at the short-circuit
duration of 1000 ms.

3. HOW TO CALCULATE THE STRENGTH LOSS DUE TO THE ANNEALING

EXPRESSED BY TEMPERATURE AND DURATION

Different equations were expressed

The Morgan’s equation [B12, B4]:

W  e ( C (ln t ) B  AT (1)
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The CIGRE equation [B12, B1]:

W  100  (134  0.24  T )  t ( 0.2410.00254T ) / d (2)

In (2), (134 – 0.24*T) has not to exceed 100, but, if so, has to be set to 100. Similarly, (0.241 – 0.00254*T) cannot
exceed 0 (zero), but, if so, has to be set to 0 [B1]. The parameters used in (1) and (2) are defined below. T and t are the
conductor temperature and the sustained time respectively with d as the conductor strand diameter. Lastly, A, B and C
are constants that depend on the conductor material.

The Goh equation [B13, B14]:

1 .6
( 0.001TC  0.095 )
W  100  k  t 0.63d (3)

Where, W is the percentage of loss of strength, d is the strand diameter [mm], t is the exposure time [hrs.], TC is the
conductor temperature [°C], and k = (- 0.24 * TC + 135). This empirical equation can be used to create a family of
annealing curves for discrete values of temperature. Loss of strength determined this way is valid only for a single
aluminum strand.

Because of some discrepancies between the results got using the Morgan and CIGRE formulae [B15], T. O. Seppa
[B16] considers CIGRE formula to be of a higher accuracy, especially mentioning the reliability of the laboratory data
got by Harvey [B17] - 110 tests for SAC, ACSR, AAAC and ACAR conductors.

The Goh equation shows some unrealistic results, if mathematically applied, especially for low values of time.

Therefore, the CIGRE equation has to be further proposed. In the Fig.3 are shown the diagrams of the remaining stress
being represented based on this equation.

Fig. 3 Remaining stress by CIGRE equation

4. WHAT FURTHER TO DO?

4.1. What is the appropriate temperature to consider for the annealing inception?

Annealing starting temperature for different aluminum alloys. May be able to be got an alloy with a higher annealing
temperature, with better mechanical and electrical characteristics and about the same price?
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Secondly, the temperatures are changing from the surface to the core of the conductor, and even changing
circumferentially. Certainly, the conductor core and surface temperatures are also changing along the span [B18]. The
simplified radial temperature formula provided by the TB 207 showed a reasonable agreement with the experimental
results [B18], based on the Morgan’s research [B19].

PT  1 D22  D 
TC  TS     ln  (4)
2πλ  2 D 2  D22  D2 

Where:

PT = the total heat gain per unit length

D = the external conductor diameter, i.e. the outer diameter
D2 = the internal diameter which is the diameter of the steel core
TS = surface temperature
TC = core temperature
 = effective radial tehermal conductivity

It is found from measurements that the mean value of radial thermal conductivity λ is about 2 W/mK.
The radial temperature difference depends on [B8]:
a) Conductor strand shape, round or trapezoidal.
b) The current in aluminum layers.
c) Electrical resistance of the strands, increasing with temperature.
d) The number of layers of aluminum wires.
e) The condition of aged conductor, like the oxidation and the bird-caging.
f) The contact area and the pressure between the aluminum layers.
The temperature difference may be ignored for short duration loads as fault currents (< 60 sec) and transient loads (5
to 30 min) [B8]. For example, the temperature differences are in the case of normal operation conditions: 11.8 for
Bluebird, 9.7 for Blue Jay, 7.5 for Drake, 6.6 for Dove, 6.3 for Hawk and 5.0 for Penquin [B8].
A graphical presentation in fig. 4.

Fig. 4 Core Temperature Rise above Surface Temperature (°C) [B8]

At high current levels, the temperature of a bare overhead phase conductor varies along each line section and even
along each span, primarily due to the variation in wind cooling [B8].
In the case of old lines has to be considered a lower factor of heat dissipation [B20].
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4.2. Choosing the worst (hottest) segment of the line

At high current levels, the temperature of a bare overhead phase conductor varies along each line section and even
along each span, primarily due to the variation in wind cooling.
The power line conductors are heated by: Joule effect (and other effects linked to electromagnetic fields) and sunshine
radiation, but a cooling is observed due to the radiation cooling given mainly by Stefan-Boltzmann law, ambient
temperature effect, convection due to wind speed and direction including effects of turbulence, spatial coherence,
conductor movement due to vibrations, buffeting, evaporation effect linked to rain and humidity effects, local heat sink
effects due to power line clamps, fittings, spacers, dampers, air craft warning markers. Some effects are local, like
clamps, spacers, slices, wire break, sensors, some are less local but not uniformly distributed along the spans, like wind
speed coherence, screening effect (by trees, building), rain effect, sunshine effects (clouds!); some are rather uniform
like ambient temperature.
At high current levels, the temperature of a bare overhead phase conductor varies along each line section and even
along each span, primarily due to the variation in wind cooling.
Therefore, the segment or even the point where the maximum temperature of the conductors is supposed to be met has
to be considered for the maximum steady state current calculation.
The evaluation of conductor temperature can be done by the following methods in accordance with the CIGRE
Technical brochure 498, June 2012, “Guide for application of direct real- time monitoring systems” [B21].
Method 1: by monitoring weather conditions along an overhead line, it is possible to calculate the local in-span
conductor temperature along the line route by placing weather instruments (measuring air temperature, solar heating
and wind speed and direction) along the line route and near to the line.
Method 2: direct in-span temperature monitors can also be placed in multiple spans to directly measure the local
conductor temperature and, if multiple monitors are placed within a line section, to determine the average line-section
conductor temperature.
Method 3: monitors can be located along the line to measure line parameters such as tension, sag, clearance (directly or
indirectly using, for example, conductor inclination or wind induced movements), which can be converted to the
average line-section temperature.
In any of these methods, the measured values must be communicated in real-time to the utility operations centers to
allow the calculation of real-time thermal line ratings.”
There have to be considered also:
- 12- 20 degrees low wind speed direction to the line axis as resulted from numerous studies [B16];
- Wind paralleling to the line [B16];
- The temperature sensors mounted on the conductors influence drastically the local temperature[B7].
4.3. Actual measures to avoid the aluminum strand annealing

There are 2 steps to be taken into account: the first to establish the right temperature difference between the outer strand
and the inner strand, as described in 7.1. and the second, monitoring the line conductor outer strand highest temperature,
as described in 7.2. and to keep it under control to not exceed a temperature of (93 – the above said difference), in
Celsius degrees.
4.4. Further tests to be performed
Annealing starting temperature for different aluminum alloys. May be can be got an alloy with a higher annealing
temperature, with better mechanical and electrical characteristics and about the same price?
Checking the mechanical characteristics of the annealed aluminum or aluminum alloy wires after different annealing
stages: Elasticity modulus, thermal expansion coefficient, stress- elongation diagrams; the loss in strength under heavy
mechanical loads (wind, ice).
Large percentage of the tensile load from the aluminum strands onto the steel core. This redistribution of load causes
extra conductor elongation, hence, greater sags than originally designed. [B3]
4.5. Concerning some assumptions

Wind velocity to be used for the conductor heating?

Which are the AC resistance values to be used for conductor heating?
 Page 7 / 8

These assumptions are still in study with IEEE at this time.

5. CONCLUSIONS
The aluminum strand annealing affects the mechanical performances of the ACSR, AAC and ACAR conductors of the
electric overhead lines, reducing the maximum tensile stresses of the aluminum strands. To avoid the annealing of the
overhead line conductors under operation, it has to be stablished the right temperature difference between the outer
strand and the inner strand and monitoring the line conductor outer strand highest temperature, to keep it under control
to not exceed a temperature of (93 – the above said difference), in Celsius degrees. Monitoring the line outer strand
temperature in the hottest points, the currents in the conductors may be limited in such a way to avoid the annealing.
For the new lines to be designed, new tests and research works have to be developed.

BIBLIOGRAPHY
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(technical brochure ELT- 114-3
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