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Copper Specification Cu+Mg
Copper Specification Cu+Mg
Copper Specification Cu+Mg
TI/SPC/OHE/CAT
(Cu- Mg) /0150(11/2016)
Technical Specification
for
for
Nov., 2016
DATE
DESIGNATION SSE (D) DD (TI) ED(TI)
COPY NUMBER
ISSUED TO ……………………………………………………………………………
INDEX
TABLE – 1
ENVIRONMENTAL CONDITIONS
SN Environmental condition Limits
i. Ambient Air Temperature. 00 C to +500 C
ii. Maximum Temperature of 700 C
metallic object under sun.
iii. Minimum Temperature. -100 C
iv. Maximum Relative humidity 100%
v. Annual Rainfall 1750mm to 6250mm
vi. Maximum number of Thunder 85
storm days per annum.
vii. Maximum number of Dust 35
storm days per annum.
viii. Number of Rainy days per 120
annum
ix. Basic wind pressure 200 kgf/m2
x. Altitude Altitude: 1000m above mean sea level.
Altitude: 2000m in J& K area.
TABLE – 2
CHEMICAL COMPOSITION OF COPPER
Element %ppm
Cu+Ag Remaining
Mg 0.1% - 0.7%
Bi < 10 ppm
Pb <5 ppm
P <50 ppm
Oxygen <20 ppm
5.2 The manufacturer of CCCM Wire Rod which is used in the manufacture of
prototype Stranded Copper-magnesium Conductor will be treated as
approved vendor for CCCM Wire Rod once the prototype Stranded Copper
Magnesium Wire manufactured by this CCCM Wire Rod is approved.
5.3 The CCCM Wire Rod or Hot Rolled Cu-Mg Wire Rod shall be suitable in
diameter for using in manufacturing the Hard Drawn Stranded Magnesium
Alloyed Copper Stranded Conductor of required size (2.10 mm). The wires
shall be stranded to finish Specification for 7/2.10mm, 19/2.10, 37/2.10 one
operation.
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8.2 Not more than four joints during stranding in 3000 m length of the stranded
conductor shall be permitted. Each such joint shall be painted to enable the
operator to identify the joint easily.
9.0 STRANDING
9.1 The conductor shall have right hand ordinary concentric lay. The successive
layers shall be twisted in opposite directions. The wires in each layer shall be
evenly and closely stranded around the underlying wire(s). The lay ratio shall
be in accordance with Table-5.
Note: Wires conform to the direction of the central part of the letter`Z’ when the
conductor is held vertically and viewed from the side. For left hand lay, the
wires conform to the central part of the letter `S’ when the conductor is held
vertically and viewed from the side.
12.1 The mechanical properties of the stranded wire shall be such that the tensile
strength when tested in accordance with Clause 18.6 shall not be less than
the appropriate value given in Table-3.
12.2 The wire shall comply with the requirement of wrapping test as given in
Clause 18.7.
TABLE – 3
PROPERTIES OF SOLID CIRCULAR MAGNESIUM COPPER (Cu-Mg) WIRES
(Before Stranding)
Nominal Resistance per
Calculat
equivale km at 20° C
ed Minimum Breaking
DIAMETER nt Weight per km corrected to
area of Load on Diameter Minimum
area of std
magnesi Tensile
hard Weight
um Strength.
drawn
copper
Std. Max. Min. copper Std. Max. Min. Std. Max. Min. Max. Std.
Wire
Wire
mm mm mm mm2 mm2 Kg Kg Kg Ohm Ohm Kgf Kgf Kgf Kgf/mm2
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)
2.10 2.12 2.08 3.464 2.858 30.83 31.42 30.26 6.221 6.342 224 233 229 66.14
NOTE : 1 The values of breaking load specified in column 11 are minimum with
which Single Wire shall comply before stranding.
NOTE : 2 The values specified in column 12 are the bases from which appropriate
breaking load of the stranded conductors listed in Table–4 have been
calculated.
TABLE – 4
PROPERTIES OF STANDARD MAGENESIUM COPPER
(Cu-Mg) STRANDED CONDUCTOR
Nominal
No. of Resistance per km at
equivalent Minimum Calculated
strands Approx. Weight Per Km. 20°C corrected to
Area of breaking area of
and overall Standard Weight
Hard load of Magnesium
diameter 0f Diameter
Drawn Conductor Copper.
Wire Std Max Min Std Max
Copper
2 2
mm mm mm Kg Kg Kg Ohm Ohm Kgf mm2
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
19.84 7/2.10 6.3 217.60 221.76 213.58 0.8958 0.9132 1432.7 24.05
53.50 19/2.10 10.5 594.40 605.78 583.41 0.3322 0.3387 3915.9 64.85
103.62 37/2.10 14.7 1163.52 1185.79 1142.01 0.1717 0.1750 7625.7 125.60
Note: 125 mm2 Magnesium Copper Catenary shall be used in place of existing
129mm2.
Note: parameters are given in the Specification are not final. The technical
parameters shall be freezed after type test vailidation.
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TABLE – 5
LAY RATIO
13.0 TESTS
13.1 After a Purchase Order is placed for supply of Magnesium Copper Catenary
Wire for overhead Railway Traction, the internal test results for all the tests
specified in Clause – 14.0 shall be furnished by the successful manufacturer
to the Director General (Traction Installation)/Research Designs & Standards
Organisation, Manak Nagar, Lucknow - 226 011, within the period stipulated
for prototype approval in the order.
13.4 All the tests specified in the specification shall be carried out at the
manufacturer's works. The manufacturer shall arrange all the necessary
machinery, apparatus, labour and assistance required for conducting the
tests without any extra cost.
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13.5 In the event of the tests not being carried through to completion at one
stretch for any reason attributable to the manufacturer and it is required for
the representative of the Director General (Traction Installation) /RDSO to go
once or several times to the works of the manufacturer or other place(s) for
continuing and/or completing the tests on the prototype (s), the
manufacturer shall reimburse to the Director General (Traction Installations)/
RDSO the cost for the representative's visits to works or other place(s) more
than once. The cost as claimed by the Director General (Traction Installation)
/RDSO shall be paid through a demand draft as advised to the manufacturer.
14 TYPE TESTS:
14.1 The manufacturer shall manufacture at least 500 m length of stranded
conductor and offer for Type Tests. The type tests shall be conducted on the
stranded conductor and on the wires before and after stranding. For carrying
out the tests on wire after stranding, the samples of stranded conductor
selected shall be opened and mixed and then three wires at random shall be
selected. The following Tests shall constitute the type tests.
i) Visual Examination of CCCM Wire Rod, Cu-Mg Wire (Hard Drawn) and
Stranded Conductor.
ii) Measurement of Diameter of individual Wire and Stranded Conductor.
iii) Measurement of weight of Wire and Conductor.
iv) Measurement of lay length and lay ratio of each layer of Stranded
Conductor.
v) Measurement of Electrical Resistance of Wire and Stranded Conductor.
vi) Tensile Test on Wires.
vii) Wrapping Test on Wires.
viii) Chemical Composition of CCCM Wire Rod and Cu-Mg Wire (Hard
Drawn)
Each test shall be conducted on three samples.
14.2 Cu-Mg Rod of suitable diameter manufactured through Vertical up-cast
process; this Rod shall be drawn in to suitable size of wires and then
stranded in to conductor in presence of representative of Director General
/TI, RDSO. These Wires and Stranded Conductors shall be type tested.
14.3 Three Wires before Stranding and three Wires after stranding shall be taken
at random for each type of test on Wires.
14.4 In case of Stranded Conductor, three samples shall be taken at random for
each type tests.
15.2 Only after clear written approval of the results of the tests on the prototype
is communicated by the Director General (Traction Installation), Research
Designs & Standards Organisation, Lucknow, to the manufacturer, he shall
take up bulk manufacture of the conductor which shall be strictly with the
same material and process of manufacture as adopted for the prototype. In
no circumstances shall be material other than that adopted during the
manufacture of the prototype be used for bulk manufacture.
15.3 SAMPLING:
One sample of Cu-Mg Stranded Conductor shall be taken from each drum for
the tests prescribed in Clause 15.1.
17.1 In addition to the tests prescribed above, the following tests shall be
conducted by the manufacturer in the course of fabrication and the records
maintained.
i) The chemical composition shall meet the requirement laid down in Clause
5.1. Facility for testing of it shall be in-house with manufacturer of Cu-Mg
Stranded Conductors.
17.2 Records of these tests shall be maintained by the manufacturer and shall be
produced to the Inspecting Engineer at the time of prototype testing /Re-
assessment /Quality Audit during Acceptance Tests.
17.3 The manufacturer shall weigh every Catenary Wire drum for tare weight and
gross weight. Records of the results of weighment shall be checked by the
Inspector at the time of acceptance test.
18.3.1The weight of wire and stranded conductor per kilometer shall be measured
by weighing three samples each of 50 cm (min.) length by a balance of
accuracy of + 1 gm for conductor and + 0.1 gm for wire.
18.4 MEASUREMENT OF LAY LENGTH & LAY RATIO OF EACH LAYER OF STRANDED
CONDUCTOR
18.4.1 The lay length, i.e. the axial length of a complete turn of the helix formed by
the wire in a layer of the stranded conductor, of each layer shall be measured
by a vernier caliper or by any other method. The measured Lay Length when
divided by the mean diameter of helix will be the lay ratio of that layer.
18.5.1 The D.C. Electrical Resistance of the wire and Stranded Conductor shall be
measured by Digital Micro-Ohm Meter or Double Kelvin’s Bridge at room
temperature. The Conductor shall be in the test room which shall be at a
reasonably constant temperature for sufficient time. The measurement shall
be made on a sample length of not less than 50 cm to an accuracy of one
part per thousand. The Inspecting Engineer shall have the right to test the
accuracy of the instrument by another wire of known resistance.
18.6.1 The load on the wire shall be applied gradually and the rate of separation of
the jaws of the testing machine shall not be greater than 10 cm per minute
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and shall be so adjusted that the total time of the testing from the moment
of the application of the load till fracture is between 15 and 60 seconds.
NOTE: The strength of Stranded Conductor in terms of the sum of the strengths of
the individual wires may be assumed to be not less than as indicated in
TABLE- 6.
TABLE – 6
MULTIPLIER CONSTANT FOR COVERSION OF
ELECTRICAL RESISTANCE TO 200C.
Multiplier constant for converting resistance of hard drawn Magnesium Copper
(wire/conductor) at any temperature between 50 C and 450 C to a temperature of
200 C is in column 2 and 5 and its reciprocal is in column 3 and 6 respectively for
converting resistance at 200 C to that at any other temperature between 50 C and
450C.
Temperature Multiplier Reciprocal Temperature Multiplier Reciprocal
0 0
C Constant of Constant C Constant of Constant
This test shall apply to wires of all diameters before stranding and also
to the wires taken from the stranded conductor. The tensile strength of
a wire before stranding when tested in the manner as explained below,
shall be not less than the appropriate value given in T ABLE-3. If it is
not possible to test the wires before stranding, the test may be made
on wires taken from the stranded conductor. In such cases the tensile
strength of any of the wire shall be not less than 92.5% of the value
given in T ABLE-3 and the average tensile strength of all the wires in a
stranded conductor shall be not less than 94% of the value specified in
TABLE-3.
18.6.2.1 The load shall be applied gradually and the rate of separation of the
jaws of the testing machine shall not be greater than 10 cm per
minute and shall be so adjusted that the total time of the testing from
the moment of the application of the load till fracture is between 15
and 60 seconds.
TABLE – 7
Number of Percentage strength based on Percentage strength
Wires in the strength of wires when based on the strength
Stranded taken from the Stranded of the wire before
Conductor Conductor and tested Stranding.
7 93 90
19 93 90
37 93 90
The average tensile strength of all the wires in a stranded conductor shall not
be less than 94% of the value specified in Table-3.
18.7 WRAPPING TEST ON INDIVIDUAL WIRE
18.7.1 The wire shall be wrapped round a wire of its own diameter to form a close
helix of 8 turns. Six turns shall then be unwrapped and then closely re-
wrapped in the same direction as the first wrapping. Wire shall not break
during the test.
18.8.1 The Copper shall have the chemical composition as given in Table-2. The
trace elements shall be determined by Spectrometric method. The Chemical
composition of Copper shall be determined in accordance with IS: 440-1964
or with the Spectrometer. For Magnesium content, certificate from the
manufacturer of Continuous Cast Magnesium-Copper Wire Rod shall be
furnished. However, Inspection authority may send the samples to
Government Approved Laboratory for verification of oxygen content.
For acceptance test one composite sample from the samples selected
from each drum shall be analyzed for copper, Mg and phosphorus content.
18.9 Weighment of three or one fifth of offered Drums whichever is higher shall be
made for Gross Weight and recorded.
19. LENGTH OF CONDUCTOR
The conductor shall be ordered in specified lengths which may vary between
500 m and 3200 m and shall be supplied as per the following tolerances.
20.1
(i) The cadmium copper stranded conductor shall be delivered to the
purchaser properly wound on either wooden drums or corrugated steel drums
2.5 MT capacity (type of drum required whether wooden or steel to be
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Appendix – ‘A’
A-1 The stranded magnesium copper conductors are used as Catenary, Bridle Wire
and terminating wire in the traction overhead equipment and are very
important components of the system. Any failure of the conductor in service
has very serious repercussions. It is, therefore, essential that the
manufacture of the conductors is to the highest standards of reliability, so as
to achieve a maintenance free service of 40-50 years.
A-2 The drawing of 2.10 mm diameter wire shall be continuous. During drawing,
spools of lengths specified by the purchaser may be cut to obtain the wire of
exact length and avoid the jointing of wire during stranding, except in the
event of breakage.
Appendix – ‘B’ to
Specification No. TI/SPC/OHE/CAT (Cu-Mg)/0150(06/2015)
B-1.0 The values of TABLE-4 have been calculated on the following basis.
B-1.1 When straightened out, each wire in any particular layer of the stranded
conductor, except the central wire, is assumed to be longer than the
stranded conductor by an amount depending on the mean lay ratio (See 5,
2) of that layer as per TABLE - 5.
TABLE - 8
B 1.2 The weight of each wire in any particular layer of a stranded conductor,
except the central wire, will be greater than that of an equal length of
straight wire by an amount depending on the mean lay ratio of that layer
as indicated in para B 1.1 above.
The area, weight and resistance of the wire have been calculated by
multiplying the corresponding values for one of the single wire of which the
conductor is composed by the constants given in TABLE - 9.
TABLE-9
MULTIPLIER CONSTANTS FOR STRANDED CONDUCTOR
This term denotes the area of a solid Continuous Cast Copper Magnesium
Wire Rod which would have the same resistance as the stranded
conductor, assuming conductivity of both to be the same. This area,
therefore, takes into account the assumed increase of resistance of each
wire except the central wire and can be determined by multiplying the area
of anyone wire by a constant given in TABLE -9. This constant is the
reciprocal of the constant for calculating the resistance.
This term denotes in rounded figures the area of a solid Hard Drawn
Copper Rod of resistance approximately equal to that of the Magnesium
Copper stranded conductor.
B 1.5 TABLE - 9 has been calculated for, and is only applicable to the standard
constructions of stranded conductors specified in this standard.
***