Is 398 Part 2 6r4qg
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IS 398 (P~~),=i:-.~~~L""
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Indian Standard
ALUMINIUM CONDUCTORS FOR OVERHEAD TRANSMISSION PURPOSES - SPECIFICATION PART 2 ALUMINIUM CONUUCTORS, GALVANIZED STEEL-REINFORCED
( Third Revision) Second Reprint OCTOBER 2001
ICS 29.240.20
(\) HIS 1996
BUREAU
OF INDIAN STANDARDS
MANAK BHAY AN.
[)(,(,C'fII!Jcr
1996
l} BAHADUR SHAH NEW DELHI 110002
ZAFAR MARG
Price Group 5
AMENDMENT NO. 1 MARCH I " , TO
IS
3.(PART 2) : I'"
ALUMINIUM CONDUcrORS
FOR OVERHEAD TRANSMISSION PURPOSESSPECIDCATION PART 2 ALUMINIUM CONDUCTORS, GALVANIZED STEEL-REINFORCED (Tlainl RnisiOll)
( Pilge S, clause 13.', (vst fNJra, formuls ) - Substitute the following {or the existing:
'R20= RT
1
l+oc (T-20)
wbere
R10 = resistancecorrected at 20°C; RT == resistance measured at -roC; QC constant mass tempenture co-efficlent of resistance, 0·004 03; and r ambieat temperature duringmeasurement.
=
=
(Ptl~ 6, cltMue 14.1(b) and (c) ] - Insed superscript '1)' at both tbe places. (PIIge 8, Table 3, col 2, row 12) - Substitute '5413.53' lor '54/4.13"
( Page 8, Table S, Heading) 'Staadlill Constants'.
Substitute 'Strandlag Constants' lor
( Pllge 8, Table S, col 2, row 1 ) - Substitute '1' for '0'.
•
(ET37)
Repropap.y Ulia. 81S. NewDel'" IDdia
AMENDMENT NO. 2 MARCH 2000
TO
IS 3'8 ( PART 2) : 1'"
ALUMINIUM CONDUCTORS
FOR OVERHEAD TRANSMISSION PURPOSES SPECIFICATION PART 2 ALUMINIUM CONDUCTORS. GALVANIZED
STEEL·REINFORCED ( TAW RnUion )
(Pllge 2, cltJusc '.1.1 ) - SUbititute '5484 : 1997' for '5484 : 1978'. ( Page2, clGusc ,.2.2 ) - Delete andrenumber tbe subsequent clauses. ( Page 2, clause '.13 ) - Deletesubheading 'Conductor' COlllainillg More Tha" SevenWires'. ( Page 2, clause '.2.3, rlrst sentence) - Delete 'For stnnded conductor containingmore thansevenwires'. (Page 3, clause 11.1 ) - Substitute CIS 1778 : 1980' for 'IS 1778 : 1981'. ( Page 3, clause lZ.l(c) and (d») - Substitute 'Net mass' and 'Gross mass' for 'Net weight' and 'Gross weight' respectively.
( Page 3, claus« 13.1.5,partl 1 ) - Delete last line. ( Page S, clause 13.6 ) -
Substitute '0.004 03' for '0.004' for
description of 'X'.
( Page 5, clause 13.9, para 1 ) - Substitute tbe following for tbe existing: 'This tTt is applicable to conductors of nominal aluminium'llel greater tban
tOOmm. . (Page S. clause 13.10. para 1 ) - Substitute the following for tbe existing: I I
'This ~t is applicable l00mm .'
to conductors of nominal aluminium area grater than
( Pale S, clause 13.10, IlISt two liM' ) - Substitute the following for the exiitilll: 'The
actull breakiDl load falls below the specified blaking Itleagth
requirement.• 1
Amend No.2 to IS 3M (Paat 2) : 1'"
(Page 5, cla. . 13.11. para 1) - Substitutethe following for the existing: 'This test is to be conducted if agreed between the purchaser and supplier'.
(Page 6, clause 13.11.3.6,llIIlliIIe ) - Substitute '13.11.3.2'101 '5.3.5'. ( Page 6, clause 13.11.5, line3 ) - Deletetbe word 'and' after '70 percent'. (Page 6, cia. . 13.11.5) -lnaert the followiug pili in the end: 'For the purpose of calculating stress-shain dati at 20°C, the following formula lI1Ay be used:
1 £20
•
£. x
1+«(1-20)
where £20 is the st~..tlin valueat 1IJ0C, and
£t
at roomtempellture.'
[ Page 6, clause 14.1(a) ) - Delete 'I)' and the corresponding footnote. ( Em37)
2
"""ph,
UIIII, SIS,NewDel........
AMENDMENT NO. 3 DECEMBER 2002 TO IS 398 ( PART 2 ) : 1996 ALUMINIUM CONDUCTORS
FOR OVERHEAD TRANSMISSION PURPOSE SPECIFICATION PART 2 ALUMINIUM CONDUCTORS, GALVANIZED STEEL -
REINFORCED (7Iltrl RnllltHl)
I Pale S, clau,. 13.6 ( lee GI,o Amellllmellll No.1 tUUl2 )] - Delete the matter in the Amendment No.2.
Pa,.
I 6, claus.tc.l(b) tUUl (c) and ,Ia~ /QOtMI. ( lee also Amerul1Mnts No. 1 and 2 ) ] Delete the superscript .1). at both the places and the corresponding footnote.
(~37)
Repropapby UBit, 81S. NewDelbi. lDdla
Conductors and Accessories for Overhead Lines Sectional Committee. ET 37
FOREWORD
This Indian Standard (Third Revision) was adopted by the Bureau of Indian Standards, after the draft finalized by the Conductors and Accessories for Overhead Lines Sectional Committee had been approved by the Electrotechnical Division Council. This standard was originally published in 1953, the first revision was brought out in 1961. In this revision, the standard had been modified in the light of the modern development in the techniques of the conductor manufacture. The other salient point incorporated in this revision was the inclusion of
wrapping test for the aluminium wires in place of the elongation test originally specified for aluminium · as well as steel wires. The second revision was brought out in 1976 and the third revision has been undertaken with a view to effecting the following considerations: To line up with the International Standards.
a)
b) All amendments approved and circulated after 1976 have been considered while preparing this standard for third revision.
c) The most important consideration bas been taken regarding improvement in conductivity of Be grade aluminium, the maximum resistivity of 0.028 264 ohm. mm2/mm at 200C as per IEC Standard. d)
Measurement of wire diameter, lay ratio, test procedure and testing of routine tests and acceptance tests have been included.
e)
Type tests have been included.
While revising this standard, it was decided to issue it in different parts covering different types of conductors. This part 'dealing with galvanized steel-reinforced aluminium conductors fonn Part 2 of the series. Other parts in this series are given below:
Part Part Part Part
I
3 4
5
Aluminium stranded conductors Aluminium.conductors, aluminized steel-reinforced Aluminium alloy stranded conductors Aluminium conductors, galvanized steel-reinforced for extra high voltage (400 kV and above).
In the preparation of this standard, assistance has been derived from the following: lEe 888: 1987 Zinc coated steel wires for stranded conductors. lEe 889: 1987 Hard drawn aluminium wire for overhead line conductors. lEe 1089: 1991 Round wire concentric lay overhead electrical stranded conductors.
as 215 : Part2 : 1970Specification for aluminium conductors and aluminium conductors. steel-reinforced for overhead power transmission: Part 2 Aluminium conductors, steel-reinforced. British Standards Instituuon.
The value of modulus of elasticity and coefficient of linear expansion are given in Annex B for information. For the purpose of deciding whether a particular requirement of this standard is complied with, the final value, observed or calculated, expressing the result of a test or analysis. shall be rounded off in accordance with IS 2 : 1960 'Rules for rounding off numerical values (revisedy , The numberof significant places retained In the rounded off value should be the same as that of the specified value in this standard.
IS 398 (Part Z) : 1996
Indian Standard ALUMINIUM CONDUCTORS FOR OVERHEAD TRANSMISSION PURPOSES - SPECIFICATION PART 2 ALUMINIUM CONDUCTORS, GALVANIZED STEEL-REINFORCED
(Third Revision) IECTION 1 GENERAL 1 SCOPE
1.3 DlretIIoa ef Lay
1.1 This standard (Part 2) covers the requirements and tests for aluminium conductors, galvanized steelreinforced used for overhead power transmission purposes.
The direction of lay is defined as right-hand or Jefthand. With right-hand lay, the wires conform to the direction of the central part of the letter Z when the conductor is held vertically. With left-hand lay, the wires conform to the direction of the central part of the letter S when the conductor is held vertically.
2 REFERENCES
3.4 Lay Ratio
2.1 The following Indian Standards are necessary adjuncts to this standard.
Ratio of the axial length of a complete turn of the helix formed by an individual wire in a stranded conductor to. the external diameter of the helix
IS No.
Title
209 : 1992
Zinc ingot (fourth revision)
4 PHYSICAL CONSTANTS FOR HARD-DRAWN ALUMINIUM
1778 : 1980
Reels and drums for bare wire (first
4.1 Resistivity
revision)
4826: 1979
Hot dipped galvanized coating on round steel wires (first revision)
The resistivity of aluminium depends upon its purity and physical condition. For the purpose of this standard, the maximum value permitted is 0.028 264 ohm mm2/m at 20°C and this value has been used for calculation of the maximum permissible values of resistance.
5484 : 1978
Be grade aluminium rod produced by continuous casting and rolling
NOTE- It IS not Intended to check the resisnvuy from the measured values of resistance.
7623 : 1993
Lithium base grease for industrial
1885 : Electrotechnicalvocabulary: Part 32 (Part 32) 1993 Electric cables (first revision)
purposes (second revision) 3 TERMINOLOGY
3.0 For the purpose of this standard, the following definitions, in addition to those given in IS 1885 (Part 32) : 1993 shall apply. 3.1 Aluminium Conductor, Galvanized SteelRelnforeed
Conductor consisting of seven or more aluminium and galvanizedsteel wires built up in concentriclayers. The centre wire or wires are of galvanized steel and the outer layer or layers of aluminium. 3.1 Diameter
The mean of two measurements at right angles taken at the same cross section.
4.2 Density At a temperature of 20 DC. the density of hard-drawn aluminum has been taken as 2.703 g1cm'.
4.3 Constant-Mass Temperature Coefficient Resistance
or
At a temperature of 20°C the constant-mass temperature coefficient of resistance of hard-drawn
aluminium, measured between two potential pomts rigidly fixed to the wire, the metal being allowed to expand freely. has been taken as 0.004 03 DC.
4.4 Coemcient of Linear Expansion The coefficient of linear expansion of hard-drawn aluminium at 0 °C has been taken as 23.0)( 10"1°C. This value holds good for all practical purposes over the range of temperature from 0 °C to the highest safe operating temperature.
IS 398 (Part 2) : 1996
SECTION 3 DIMENSIONS AND CONSTRUCTION
S PHYSICAL CONSTANTS FOR GALVANIZED STEEL WIRES 5.1 Density
8 STANDARD SIZES
At a temperature of 20°C, the density of galvanized
8.1 Wires
steel wire is to be taken as 7.80 g1cm" 8.1.1 Nominal Sizes 5.2 Coemcient at Linear Expansion
TIle aluminium and galvanized steel wires for the standard constructions covered by this standard shall have the diameter specified in Tables I and 2. The diameterof the galvanized steel wire shall be measured over the zinc coating.
In order to obtain uniformity in calculation, a value of 11.5x 10·"/oC may be taken as the value for the coefficient of linear expansion of galvanized steel wires used for the cores of steel-reinforced aluminium conductors.
8.2 Aluminium Conductors, Galvanized SteelReinforced
SECTION 2 MATERIALS 6
8.2.1 The sizes of stranded aluminium conductors, galvanized steel-reinforced shall be as given in Table 3.
MATERIAL
6.1 The conductorshall be constructed of hard-drawn aluminium and galvanized steel wires which have the mechanical and electrical properties specified in Tables 1 and 2.
8.2.2 The resistance shall be in accordance with Table 3. The mass (excluding the mass of grease, if applied) are given in Table 3 for information.
6.1.1 The Ee grade aluminium rods for use in the manufacture of aluminium wires shall conform to IS 5484: 1978.
9 T IN WIRES 9.1 The wires shall be drawn in continuous length, without ts, except those made in wire rod or before drawing operation.
6.1.2 Galvanized steel wire should be drawn from high carbon steel rods produced by either acid or base open hearth process, electric furnace or basic oxygen process. The mechanical properties of wire shall comply with the requirements given in Table 2. The chemical compositions of high carbon steel wire is given in Annex C for the purpose of guidance.
9.2 ts in Aluminium Stranded Wires
9.2.1 During stranding in aluminium wire no welds shall be made for the purposeof achieving the required conductor length.
6.2 The zinc used for galvanizing shall be electrolyte high grade zinc not less than 99.95 percent purity. It shall conform to and satisfy all the requirements of IS 209: 1992.
9.2.2 Conductor Containing Seven Wire.\'
ts in wires other than those permitted under 9.1 shall not be permitted in any wire of stranded conductor containing seven wires.
The coating on the galvanized steel wires may be applied by the hot process or the electrolytic process. When specified by the purchaser, neutral grease may be applied between the layers of wires.
9.2.3 Conductors Containing More Than Seven Wires
For stranded conductor containing more than seven wires, ts are permitted in wire broken during stranding provided such breaks are not associated with either inherently defective wire or with those of short lengths of aluminium,wires. ts shall be dressed smoothly with a diameter equal to that of parent wires and shall not be kinked. No two ts other than those in wires before stranding permitted under 9.1 occur at points in the stranded conductors nearer than 15 In.
6..3 When specified by the purchaser, neutral grease has to be applied as per one of the following cases: a)
Steel core only,
b) All conductor except outer layer,
c) All conductor including outer layer, and d) All conductorexcept outer surfaceof the wires in the outer layer.
9.2.4 ts shall be made by electric butt welding. electric butt cold upset welding or' cold pressure welding. These jomts shall be made in accordance with good commercial practice. Electric butt welding shall be annealed for approximately 250 mm on both sides of the welds,
NOTE- Luhium soap grease corresponding to Grade II of IS 7623 199:\ haVing mmunum drop point not less than 180"C is suitable for such application,
7 FREEDOM FROM DEFECTS 7.1 The wires used for standard conductor shall be smooth and free from imperfections, such as spills and splits.
While the ts specified are not required to meet the requirements of unted Wires, they shall
9.2.5
2
IS 398 (Part 2) : 19M be withstandinl a stress of not less than 75 MPa for
annealed electric butt wel4ed ts and not less than 130 MPafor cold pressure andelectric buttcold upset welded ts. The manufacturer shall demonstrate that the proposed welding method is capable of meeting the specified strength requirements.
9.3 Jolatl In J}alvaaIIed I
stele 'I
Wins
No ts of any kind shall be made in the finished coated steel wires. 10
STRANDlNG It
•
10.1 The wires used in the c~nstruction of a galvanizedsteel-reinforced aluminiumconductorshall, before stranding, satisfy all the relevant requirements of this standard.
to IS 1778 : 1981 be used) and marked with the following· a) Manufacturer's name, ,,) Size and type of conductor, c) Net weisht of conductor in kl, d) Gross weight of cOP"lIctor in kg, and e) Length Qf conductor in m.
11.1.1 The conductor may also be marked with the SIS Standard Mark.
12.1.2 The use of Ule Standard Mark is governed by the provisions of ~e Bureau 0/ Indian SltIndDrds Act, 1986 and t~e Rules and Regulations made thereunder. The details of conditions under whic~ a licence for the use of the Stan~ard Mark may be granted to manufacturers or producers may be obUli~ from the Bureau of Indian 'Standards.
lQ.Z The lay ratio of the different layers shall be within the limits given in Table '4. . ,. 10.3 The ratio of the nominal dj~meter of the aluminium wires to the nominal "diameter of the galvanized steel wires in any particular construction of galvanized steel-reinforced aluminium conductor, shall conform to the appropriate value given in Table 4. 10.4 In all constructions, the successive layers shall have opposite directions of lay, the outermost layer being right-handed. The wires in each layer shall be evenly and closely stranded.. 10.5 In conductors having multiple layers of aluminium wires. the lay ratio of any aluminium layer shall be not greater than the lay ratio of the aluminium layer immediately beneath it. 10.6 Steel wires shall be formed during stranding so that they remain intact when conductor is cut for jomting operation,
11 LENGTHS AND VARIAnONS IN LENGTHS 11.1 Unless otherwise agreed to between the purchaser and the manufacturer, galvanized steel reinforced aluminium conductor shall be supplied in the manufacturer's usual production lengths and with a permuted variation of ±5 percent jn the length of anyone conductor length.
Unless otherwise agreed to between the purchaser and the manufacturer, it shall be permissibleto supply not more than 10 percent of the lengths on anyone order In random lengths; none of them shall be shorter than one-third of the nominal length. PAp~ING
AND
~ARKING
12 PACKING AND MAltK1NG
1.2.J TIle conductorshall be woundon reels or drums
13 TESTS 13.1 Selection of Test Samples for Acceptance and Routine Test r
13.1.1 Samples of individual wires for tests specified in 13.2, 13.3.1, 13.4, 13.5, 13.6, 13.7 and 13.8 shall normally be taken by the manufacturer before stranding, from the outer ends of not less than 10 percent of wire coils.
13.1.1 Alternatively. if desired by the purchaser at the time of placing an order that the tests be made in the presence of his representative, samples of wire shall be taken from lengths of stranded conductors. Samptes shall then be obtained by cutting 1.2 m from the outer end of the finished conductor from not more than 10 percent of the finished reels or drums. If there is more than one length on any reel or drum, the sample shall be taken from the outer length. 13.1.3 Coils offered for inspection shall be divided (this may be done physically or on the basis of ~dentificalion numbers of the coils offered for supply) Into equal lots, the number of lots being equal to the number of samples to be selected. a fraction of a lot being counted as a complete lot. One sample coil shall be selected at random from each lot. 13.1.4 For the purposeof various tests, one specimen
means one sample of the conductor.
11.2 Random Leolths
SECTION 4
SECTION 5 TESTS
recommended that reels and drums conformmg
13.1.5 Type test shall be conducted at the works of the finn and if such facilities are not available, the same shall be got conducted at some test house agreed to between the purchaser and the supplier against each order in the presence of the purchaser. The supplier shall offer at least three drums of each size of conductor for selection of samples required for type test. Type test certificate of test house for same size of conductor carried out earlier shall be acceptable If agreed to between the purchaser and the supplier.
IS 398 (Part 2) : 19M 13.2 Mea.uremeDt 01 Diameter 01 ladlvldual AluminiulD Wires and Galvanized Steel Wires
NOTS - Portwoormen frIct... oc:aaNdduriD.lWildna. die filii fract. . would be c:aIIed • primary frIIdure aad die sublequent frac:hna would be called .,1eCOIIdarY frIcruJeI.
One sample cut from each of samples taken under 13.1.1 and 13.1.2 shall be measured using a micrometer having flat surface on both the anvil and the end of the spindle (0 be read with micrometer. The diameter in millimetre shall be average of three diameter measurements, each of which is the average of the maximum reading at a point taken near each end and in the centre of the sample.
When telted after strandin" the number of complete twists before fracture occun shan be not less dian 16 on a length equal to 100 times' the diameter of the wire. Tbe fracture shall show a smooth surface at right angles to the axis of the wire. 13.4.2 Elongation
The diameter of the wire shan be within the limit as specified in Tables 1 and 2.
T~st
The elongation of one specimen cut from each of the samples taken under 13.1.1 (I' 13.1.2 shall be determined. The specimen shall be straightened by hand and an original gauge length of 200 mm shall be marked on the wire. A tensile load shall be applied as described in 13.3.1 and the elongation shall be measured after the fractured ends have been fitted together. If the fracture occurs outside the gauge mark, or within 25 mm of either mark and the required elongation is not obtained, the test shall be disregarded and another test made.
13.3 BreaklDI Load Test
This test shall be made on both aluminium and galvanized steel wires. 13.3.1 The breaking load of one specimen cut from each of the sample taken under 13.1.1or 13.1.2shall be determined by means of a suitable tensile testing machine. The load shall be applied gradually and the rate of separation of thejaws of the testing machine shall be not less than 25 mm/min and not greater than 100 mm/min.
When tested before stranding, the elongation shall be not less than 4 percent. When tested after stranding, the elongation shall· be nbt less than 3.5 percent.
The ultimate breaking load of the specimens- shall be not less than the appropriate value specified in Tables I and 2.
NOTE - The sample has 10 either the torsion tell or elonption test, thai is, if the conductor is pOllina any of the two tests, the sample should be col1lidered II in,.
13.4 Ductility Test
13.5 Wrappinl Tad...
This test shall be made on galvanized steel wires only, by any of the procedures given in 13.4.1 and 13.4.1.
This test shall be made on both aluminium and galvanized steel wires.
13.4.1
13.5.1
Torsion Test
One specimen cut from each of the samples taken under 13.1.1 (I" 13.1.1 shall be gripped at its ends in two vices one of which shall be free to move longitudinally during the test. A small, tensile
Aluminium Wires
One specimen cut from each of the samples of aluminium wire taken under 13.1.1 and 1~.1.1 shall be wrapped round a wire of its own diameter to form a close helix of eight turns. Six turns shall then be unwrapped and again closelyt wrapped in the same direction as before. The wire shall not break.
load not exceeding 2 percent of the breaking load of the wire, shall be applied to the sample during testing. The specimen shall be twisted by causing one of the vices to revolve until fracture occurs and the number of twists shall be indicated by a counter or other suitable device. The rate of twisting shall not exceed 60 rev/min.
13.5.2 Galvanized Steel Wires
One specimen cut from each of the samples of galvanized steel wire taken under 13.1.1 cr 13.1.2 shall be wrapped round a mandrel of diameter equ~ to 4 times the wire diameter to fonn a close helix of 8 turns. Six turns shall then be unwrapped and againcloselywrapped in the same directionas before. The wire shall not break.
The test may be carriedout on gaugelength~f I SO Jl.lrn for all wire sizes when the number of twists, which the wire shall withstand, shall be direct ratio to the numbers specified for 100 times the diameter of the wires.
13.6
Whentested beforestranding, the numberof complete twists before fracture occurs shall be not less than 18 on a length equal to 100 times the diameter of the wire.
Resistance Test
This test shall be made on aluminium wires taken before stranding or after strandin•. NOTE - The resistance of individUli wi-a ....1be .uch dill the completed IlrudecI conductor meeII Ihe of the maximum rai.tance specified in Tlble 3 calcu"" by applyinl the relevant strandin. co...... liven 1ft Table ~.
_Ie'"
The primary fracture ~hall show. a smooth surface at ri,ht angles to the axis of the wire. Any secondary fracture shall be ignored. 4
IS 398 (Part 2) : 1996 The electrical resistance of one specimen of aluminium wire cut from each of the samples taken under 13.1.1 (l" 13.1.2 shall be measured at ambient temperature.
A sample of conductor of minimum S m length suitably clamped ~t either end. The load shall be increased at a steady rate up to rated ultimate breaking load and held for one minute. When so tested, the conductor shan not show any fracture. The applied load shall then be increased until the failing load is reached and the value recorded. A re-test up to a total of three tests, may be made if wire fracture occurs ~ithin one centimetre of the end fittings and the tensile strength falls below the specified breaking strength requirement.
The measured resistance shall be corrected to the value at 20 OC by means ~f the formula: I - X (T - 20) where resistance corrected at 20°C; resistance measured at T °C;
13.11
= constant-mass temperature coefficient of resistance. 0.004; and T
Stress-Strain Test
This test is applicable to conductors of nominal aluminum area 100 mm' and above.
= ambient temperature during measurement.
13.11.1 This test is contemplated only to collect the creep data of the conductor from the supplier. A sample of conductor of minimum 10 m length shall be suitably compressed with dead end clamps.
The resistance corrected at 20°C shall be not more than the maximum value specified in Table I.
13.7 Galvanizing Test
13.11.2 Test Set-up
This test shall be made on galvanized steel wires only.
13.11.2.1 The test sample shall be ed in a trough over its full length and the trough adjusted so that the conductor will not be lifted by more than 10 mm under tension. This shan be ascertained by actual measurement.
13.7.1 This test shalt be made on one specimen cut from each of the samples of the galvanized steel wires taken under 13.1.1
13.11.2.2 The distance between the clamp and the sleeve mouth shall be monitored with callipers during the test to ensure that. after the test. it does not change by more than I mm ± 0.1 from the value before the test.
13.8 Measurement of Lay RatlolDirection of Lay The lay ratio of each layer of the conductor shan be measured and checked as per the requirements specified in Table 4, 10.5 and lay direction shan be as per requirement of 10.4.
13.11.2.3 The conductor strain shall be evaluated from the measured displacements at the two ends of the gauge length of the sample. The gauge reference targets shall be attached to the clamps which lock the steel and aluminium wires together. Target plates may be used with dial gauges or displacement transducers and care shall be taken to position the plates perpendicular to the conductor. Twisting the conductor, lifting it and moving it from side-to-side by the maximum amounts expected during the test should introduce not more than 0.3 mm error in the reading.
13.9 Surface Condition Test This test is applicable to conductors of nominal aluminium area 100 mm! and above. A sample of the finished conductor having a minimum recommended length of S m with compression type dead end clamps compressed on both ends in such a manner as to permit the conductor to take its normal straight line shape, shall be subjected to a tension of SO percent of the ultimate breaking load of the conductor.
13.11.3 Test Loads for Complete Conductor The loading conditions for repeated stress-strain tests for complete conductor shall be as follows.
The surface shan not depart from its cylindrical shape nor shall the strands move relative to each other so as to get out of place or disturb the longitudinal smoothness of the conductor. The measured diameter at any' place shall be not less than the sum of the minimum specified diameter of the individual aluminium and stee,l strands as indicated in Tables I and 2 of this standard.
13.11.3.1 I kN load shall be applied initially to straighten the conductor. The load shall be removed after straightening and then the strain gauges are to be set at zero tension. 13.11.3.2 For non-continuous stress-strain data, the strain readings at I kN intervals at lower tensions and S kN intervals above 30 percent of ultimate breaking load shall be recorded.
13.10 Test lor Ultimate Breaking Load on
Stnaded Coaductor
13.11.3.3 The sample shall be reloaded to SOpercent of ultimate breaking load and held for I h. Reading
This test is applicable to conductors of nominal aluminium area 100 mm' and above.
s
IS _
(Part 2) :
1'" c) Stress-strain test (13.11),
are to be noted after " lO, 15, 30. 45 and 60 min durinl the hold period. The load shall be mleued after the hold period.
d) Mouuremcnt of diameter of individual aluminium ·and sJeel wires (l~.J~,
13.11.3.4 RelOldinl up to 70 percent of ultimate breakinl load be done and"eld for I h.lteadin,. are to be noJed after 5. lQ. '5, 30, 45 and 60 min",•. The load .hall then be released.
1hII'
-
e) Meuurement of lay ratio (13.'), f) Breakinl load of individual wires (13.3.1),
13.11.3.5 Reloadin. up to 85 percent of ultimate breakinlload shall be done and he'd for I h. Readin, are to be noted after " 10, 15, 30, 45 and 60 minutes and then load shall be released. I
,) Ductility lest (13.4),
13.11.3.6 Tension shall be applied a,ain and shall be increased uniforml~ .until the actual ~reaki~1
k) Oalvanizina test (13.7).
\
h) Wrapping test (13.5), j) Resistance test
T~st
Ltx.uls for
St~"
and
I
stren.th is reached. Simultaneous readlnls of tension and elongation shall be recorded up to 90 percent of ultimate breakins load at intervals described under 1.3.5. 13.1l.4
(t3.~),
14.2
Cor, Only
Accepta~e
Tests
a)
Measurement of diameter of individual aluminium and steel wires (s~e 13.2),
b)
Measurement of lay ratio (see 13.8),
The loading condition of repeated stress-strain tests for the steel core of ACSR shall be as follows.
c)
Breaking load of individual wires (see
13.11.4.1 The test shall consist of successive application of -load applied in a manner similar to that for the complete conductor at 30 percent, SO percent, 70 percent and 8S percent of ultimate breaking load.
d) Ductility test (see 13.4),
1~.3.1).
13.11.4.2 The steel core shall be loaded until the elongation at the beginnin, of each hold period corresponds to thatobtained on the complete conductor at 30 percent, SO percent, 70 percent and 8S percent of ultimate breaking load respectively.
Wrapping test (see 13.5),
t)
Resistance test (see 13.6), and
g)
Galvanizing test
(see 13.7).
14.3 Routine Test The routine tests shall be done same as acceptance tests and shall be carried out before and after stranding.
13.11.5 Stress-Strain Curves The design stress-strain curve shall be obtained by drawing a smooth curve through the 0.5 and 1 h points at 30 percent, SO percent and 70 percent and of ultimate breakinlload loadings. The stress-strain curves shall be submitted to the purchaser alongwith test results. The stress-straln data obtained during the test shall be corrected to the standard temperature that is 20 "C.
15 REJECTION AND RETESTS 15.1 Shouldanyone of the test pieces first selected
rail to the tests, three further samples from the same batch shall be selected, one of which shall be from the length from which the original test sample was taken. unless that length has been withdrawn by the supplier.
14 CLASSIFICATION OF TESTS
15.2 Should all of the three test pieces from these additional samples satisfy the requirements of the tests, the balch represented by these samples shan be deemed to comply with the standard. Should the test pieces from any of the three additional samples fail, the balch represented shall be deemed not to comply with the standard,
14.1 Type Tests "a) Surface condition test (see 13.9), b) Test for ultimate breaking load on stranded conductor (see 13.10),
I'
e)
Apphcable for conducton of DOlnlnw AlumlRluln Area 100 mm'
ond above
6
IS 398 (Part 2)
1996
SECTION' 6 TABLES Table 1 Aluminium Wires Used in the Construction of Aluminium Conducton, Galvanized Steel-Reinforced (Clauses 6.1, 8.1.1, 8.1.2.1, 13.2, 13.3.1., 13.5.1 and 13.6) Diameter
Cross Sectional Area of Nominal Diameter Wire
Mass
Resistance 3)
A
A Min
Mt~
(I)
(2)
(3)
(4)
(5)
(6)
mm
mm
mm
mm'
kg/kin
Ohrnsrkm
1.50 1.96
1.48 1.94· 2.09 2.56 2.97
1.52 1.98 2.13 2.62 3.03 3.21 3.38 3.54 3.57 3.84 4.13 4.17 4.77
1.767 3.017 3.497 5.269 7.069 7.942 8.814 9.621 9.787 11.34 13.14 13.40 17.50
4.78 8.16 9.45 14.24 19.11 21.47 23.82 26.01 26.45
16.432 9.561 8.237
rNominnl
2.11 2.59 3.00 3.18
s.as
3-.50
3.S3 3.80 4.09 4.13 4.72
s.is 3.32 3.46 3.49 3.76 4.05 4.09 4.67
Breaklnl Load, Mill
-c
",. Before Stranding (1)
35.51 36.21 47.30
kN
0.32 0.54 0.63 0.89 1.17 1.29 .1.43 1.55 1.57 1.80 2.08 2.13 2.78
4.079 3.626 3.265 3.006 2.954 2.545 2.194 2.151 . 1.650
30.65
(8)
kN
5.490
'-.
After Stranding
0.30 0.51
0.60 0.85 1.11 1.23 1.36 1.47 1.49 1.11 1.98 2.02 2.64
NOlE - The resistance has been calculated from the maximum value of resistivity and the cross sectional area based on the minimum diameter.
Table 2 Steel Wires Used in the Constructten of Aluminium Conductors, Galvanized Steel-Reinforced (Clauses 6.1, 8.1.1, 13.2 and A-3.2) Cross Sectional Area of Nominal Diameter Wire
Diameter
Nominal
r
Mi" /'\ (2)
(3)
mm
mm
I.~O
1.47
1.57 1.96 2.11 2.30 2.59
1.~4
1.53 1.60
l.OO
3.18 3.35 3.~3
4,l)9
1.92 2.07
2.2S. 2.54 2.94 3.12 3.28 146 4.01
Before (S)
Stranding (6)
kg/kin
kN
13.78 15.10
2.46 2.70 4.20 4.60 5.46 6.92 9.29 10.43 11.58 12.86 17.27
.......
(I)
2.()() 2.15 2.35 2.64 3.06 3.24 3.42
160 4.17
Min /\
,
MIIX
rnm
Breaking Load,
Ma.u
(4) mm' 1.767 1.936 3.017 3.497
23.S3 27.27 32.41 41.09 55.13 61.95 68.75 76.34 102.48
4.1~~
5.269 7.069 7.942 8.814 9.787 13.14
7
After Stranding (7) kN 2.34 2.57
3.99 4.37 5.19 6.57 8.83 9.91 11.00 12.22 16.4
IS 398 (Part 2) : 1996 Table 3 AllIIIlinIum CODdueton, Galvanized Steel-Relnlorced (Clmues 8.2.1.. 8.2.2 tnI A-3.2)
strandlal . .
NomIMI
SedIonaI Ara 01 AIumI"'m
Wire Dlmaeter A ,# Steel Aluminium
Alumlalum
ApproDute App.......... M_ DIameter
Calaalated
Resistance at 28°C, Max
Are."
(I)
(2)
(3)
(4)
(')
(6)
mm2
mm
mm
nun'
mm2
mm
(7) kglkm
10
611.50
I/l.SO
10.60
12.37
4.S0
43
Approximate -Calculated Brakln. Load
(8)
(9)
Ohmlkm
kN
2.780
3.97
1.618 1.394
6.74 7.61
18.10 20.98
21.12 24.48
S.88 6.33
73
1/4.09
31.61 S2.88 78.83
36.88 61.70 91.97
7.77 10.OS 12.27
128 214 319
0.928 9 0.552 4 0.371 2
11.12 11.25 26.91
614.72
7/1.57
105.0
III.~
300.59
7f2.S9 713.00
ISS.I 212.1
194.9 261.5
14.IS 18.13 21.00
394 726 974
0.279 2 0.187 I 0.139 0
32.41 67.34 89.67
713.18 7/3.53
404.1 428.9 528.5
425.2 484.5 597.0
26.88 28.62 31.77
1281 1621 1998
0.073 II 0.068 68 O.OSS 95
88.79 130.32 159.60
712.30
562.7
591.7
31.68
1781
0.052 31
120.16
18
611.96
1/1.96
20
612.11
112.11
30 50 80
612.59 613.35 614.09
112.59 113.35
100
ISO 200
3013.00
400 420 520
4213.50 5413.18 5414.13
7/1.96
560
42/4.13
NOTE - For the bais of calculation of this table I)
Total SectIonal
8S
(.w Annex A).
The sectional area is the sum of the cross-sectional areas of the relevant individual wires.
Table 4 Lay Ratios 01 Aluminium Conductors, Galvanized Steel-Reinforced (Clauses 10.2, 10.3 and 13.8) Number 01 Wires
'AJumiRi~
Sai"
1b,Io of Aluminium Wire
Lay Ratios for Steel Core
DIameter
(6 Wire
to Steel
Layer)
~
Outennost Layer
Lay Ratios for ~umlnlum Wire . . ...... Layer hnmediately Innermost Layer of
Beneath Outermost Layer
Wire DIameter~~~
Conductors with 3 Aluminium
~
Min
M,u
Min
MilX
Mit.
MtlX
Min
MtlX
(2)
(3)
(4)
(~)
(6)
(7)
(8)
(9)
(10)
(11)
6
1 7
1.0 3.0 1.0
10
6 30
13 13
10
14 14 14
1.8
13
10
13
10 10 10
16 16
1.0
28 28 28 28
16
10
17 17
(I)
7 7 7
42
S4
10
10 10
14
14
NOTE - For the purpose of calculation. the meen lay ratio shall be taken as the arithmetic mean of the relevant minimum and maximum values Jiven in this table.
Table 5 Standing Constants (Table I and Clauses 13.6. A-2. r, A-2.2 and A-2.3.1) Mass
Num.her of Wires In Conductor
,Aluminium (I)
/\
"
Steel (2)
r Al umlnlUln " (3)
A.
,
Strandin. Constant Electrical Resistance
Steel (4)
(~)
6
0
6.091
1.000
0.169 2
6
7
6.091
7.032
0.169 2
30
7
30.67
7.032
0.034 08
42
7
42.90
7.032
0.024 32
~4
7
55.23
7.012
0.018 94
8
IS 398 (Part 2) : 1996
ANNEX A (Table 3) NOTES ON CALCULATION OF RESISTANCE, MASS AND BREAKING LOAD A-I INCREASE IN LENGTH DUE TO
A-2.3 In calculating the stranding constants in Table 5. the mean lay ratio, that is, the arithmetic mean of the relevant minimum and maximum values in Table 4. has been assumed for each layer.
STRANDING A-I.I When straightened out, each wire in any particular layer of standard conductor, except the centtal wire. is longer than the stranded conductor by an amount depending on the lay ratio of that layer.
A-3 CALCULATED BREAKING LOAD OF CONDUCTOR A-3.t The breaking load of an aluminium conductorgalvanized steel, reinforced in of the sum of the strength of the individual component wires, may be taken to be as follows:
A-2 RESISTANCE AND MASS OF CONDUCTOR
A-2.1 In aluminiwn conductors, steel reinforced the conductivity of the steel core is neglected and the resistance of the conductor is calculated with reference to the resistance of the aluminium wires only. The resistance of any length of stranded conductor is the resistance of the same length of anyone aluminium wire multiplied by a constant, as set out in Table 5. A-2.2 The mass of each wire in a length of stranded conductor, except the central wire, will be greater than that of an equal length of straight wire by an amount depending on the lay ratio of the layer (see A-I.I). The total mass of any length of conductor is, therefore, obtained by multiplying the mass of an equal length of straight wire by the approximate constant set out in Table 5. The masses of the steel core and aluminium wires are calculated separately and added together.
a)
98 percent of the sum of the breaking loads of the aluminium wires plus 89 percent of the sum of the breaking loads of the galvanized steel wires, when taken from the stranded conductor and tested; or
b)
98 percent of the sum of the breaking loads of the aluminium wires plus 85 percent of the sum of the breakingloads of the galvanizedsteel wires, based on the breaking loads of the component wires before stranding, that is, in the coil.
A-3.2 The values of approximate breaking load of conductors. given in Table 3 have been calculated in accordance with (b) above and on the basis of the minimum breaking loads of the component wires given in Table I and 2.
ANNEX B (Foreword) MODULUS OF ELASTICITY AND COEmCIENT OF LINEAR EXPANSION
No. of Wires
r
/\
Aluminium
Steel
(1)
(2)
6
I 7 7 7 7
6 30 42 54
"
Final Modulus of
Coefficient of Linear
Elasticity (Practical) GN/m2
Expansion / °C
(3)
(4) 19. J x 10·" 19.8 x 10'(\
79 75 80 62
69
17.8
X
10-19
21.5 x 10'" 19.3 x 10.(\
NOTES 1 2
3 4
These values are given for infonnation only. Moduli values quoted may be regarded as being accurate to within ± 3 GN/m'. Moduli values quoted may be taken as applying to conductors stressed between 15 and 50 percent of the ultimate strength of the conductor. Coefficients of lineAl' expansion have been calculated from the final (pmctical) l1¥Xluli for the aluminium and steel components of the conductors and coefficientsof linear expansion of 23.0 x I()-6 nnd II 5 )( I~ I °C for aluminiuln and steel respectively.
ANNEX C (Clause 6.1.2) CHEMICAL COMPOSITION OF HIGH CARBON STEEL
Element
C·l The chemical composition of high carbon steel used in the manufacture of steel wire of ACSR
Manganese Phosphorus Sulphur Silicon
conductor is given below for guidance: Element
..Carbon
Percentage Composition 0.50 to 0.85 9
Percentage Compositior 0.50 to I. 10 Max to 0.035 Max 0.045 0.10 to 0.35
Bureau or lodlan Standards
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AmeDdmeDts Issued SiDce PubUcatioD
Amend No.
Date of Issue
TextAffected
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RE;." .. .•...
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#
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1P.o:L
Indian Standard
ALUMINIUM CONDUCTORS FOR OVERHEAD TRANSMISSION PURPOSES - SPECIFICATION PART 2 ALUMINIUM CONUUCTORS, GALVANIZED STEEL-REINFORCED
( Third Revision) Second Reprint OCTOBER 2001
ICS 29.240.20
(\) HIS 1996
BUREAU
OF INDIAN STANDARDS
MANAK BHAY AN.
[)(,(,C'fII!Jcr
1996
l} BAHADUR SHAH NEW DELHI 110002
ZAFAR MARG
Price Group 5
AMENDMENT NO. 1 MARCH I " , TO
IS
3.(PART 2) : I'"
ALUMINIUM CONDUcrORS
FOR OVERHEAD TRANSMISSION PURPOSESSPECIDCATION PART 2 ALUMINIUM CONDUCTORS, GALVANIZED STEEL-REINFORCED (Tlainl RnisiOll)
( Pilge S, clause 13.', (vst fNJra, formuls ) - Substitute the following {or the existing:
'R20= RT
1
l+oc (T-20)
wbere
R10 = resistancecorrected at 20°C; RT == resistance measured at -roC; QC constant mass tempenture co-efficlent of resistance, 0·004 03; and r ambieat temperature duringmeasurement.
=
=
(Ptl~ 6, cltMue 14.1(b) and (c) ] - Insed superscript '1)' at both tbe places. (PIIge 8, Table 3, col 2, row 12) - Substitute '5413.53' lor '54/4.13"
( Page 8, Table S, Heading) 'Staadlill Constants'.
Substitute 'Strandlag Constants' lor
( Pllge 8, Table S, col 2, row 1 ) - Substitute '1' for '0'.
•
(ET37)
Repropap.y Ulia. 81S. NewDel'" IDdia
AMENDMENT NO. 2 MARCH 2000
TO
IS 3'8 ( PART 2) : 1'"
ALUMINIUM CONDUCTORS
FOR OVERHEAD TRANSMISSION PURPOSES SPECIFICATION PART 2 ALUMINIUM CONDUCTORS. GALVANIZED
STEEL·REINFORCED ( TAW RnUion )
(Pllge 2, cltJusc '.1.1 ) - SUbititute '5484 : 1997' for '5484 : 1978'. ( Page2, clGusc ,.2.2 ) - Delete andrenumber tbe subsequent clauses. ( Page 2, clause '.13 ) - Deletesubheading 'Conductor' COlllainillg More Tha" SevenWires'. ( Page 2, clause '.2.3, rlrst sentence) - Delete 'For stnnded conductor containingmore thansevenwires'. (Page 3, clause 11.1 ) - Substitute CIS 1778 : 1980' for 'IS 1778 : 1981'. ( Page 3, clause lZ.l(c) and (d») - Substitute 'Net mass' and 'Gross mass' for 'Net weight' and 'Gross weight' respectively.
( Page 3, claus« 13.1.5,partl 1 ) - Delete last line. ( Page S, clause 13.6 ) -
Substitute '0.004 03' for '0.004' for
description of 'X'.
( Page 5, clause 13.9, para 1 ) - Substitute tbe following for tbe existing: 'This tTt is applicable to conductors of nominal aluminium'llel greater tban
tOOmm. . (Page S. clause 13.10. para 1 ) - Substitute the following for tbe existing: I I
'This ~t is applicable l00mm .'
to conductors of nominal aluminium area grater than
( Pale S, clause 13.10, IlISt two liM' ) - Substitute the following for the exiitilll: 'The
actull breakiDl load falls below the specified blaking Itleagth
requirement.• 1
Amend No.2 to IS 3M (Paat 2) : 1'"
(Page 5, cla. . 13.11. para 1) - Substitutethe following for the existing: 'This test is to be conducted if agreed between the purchaser and supplier'.
(Page 6, clause 13.11.3.6,llIIlliIIe ) - Substitute '13.11.3.2'101 '5.3.5'. ( Page 6, clause 13.11.5, line3 ) - Deletetbe word 'and' after '70 percent'. (Page 6, cia. . 13.11.5) -lnaert the followiug pili in the end: 'For the purpose of calculating stress-shain dati at 20°C, the following formula lI1Ay be used:
1 £20
•
£. x
1+«(1-20)
where £20 is the st~..tlin valueat 1IJ0C, and
£t
at roomtempellture.'
[ Page 6, clause 14.1(a) ) - Delete 'I)' and the corresponding footnote. ( Em37)
2
"""ph,
UIIII, SIS,NewDel........
AMENDMENT NO. 3 DECEMBER 2002 TO IS 398 ( PART 2 ) : 1996 ALUMINIUM CONDUCTORS
FOR OVERHEAD TRANSMISSION PURPOSE SPECIFICATION PART 2 ALUMINIUM CONDUCTORS, GALVANIZED STEEL -
REINFORCED (7Iltrl RnllltHl)
I Pale S, clau,. 13.6 ( lee GI,o Amellllmellll No.1 tUUl2 )] - Delete the matter in the Amendment No.2.
Pa,.
I 6, claus.tc.l(b) tUUl (c) and ,Ia~ /QOtMI. ( lee also Amerul1Mnts No. 1 and 2 ) ] Delete the superscript .1). at both the places and the corresponding footnote.
(~37)
Repropapby UBit, 81S. NewDelbi. lDdla
Conductors and Accessories for Overhead Lines Sectional Committee. ET 37
FOREWORD
This Indian Standard (Third Revision) was adopted by the Bureau of Indian Standards, after the draft finalized by the Conductors and Accessories for Overhead Lines Sectional Committee had been approved by the Electrotechnical Division Council. This standard was originally published in 1953, the first revision was brought out in 1961. In this revision, the standard had been modified in the light of the modern development in the techniques of the conductor manufacture. The other salient point incorporated in this revision was the inclusion of
wrapping test for the aluminium wires in place of the elongation test originally specified for aluminium · as well as steel wires. The second revision was brought out in 1976 and the third revision has been undertaken with a view to effecting the following considerations: To line up with the International Standards.
a)
b) All amendments approved and circulated after 1976 have been considered while preparing this standard for third revision.
c) The most important consideration bas been taken regarding improvement in conductivity of Be grade aluminium, the maximum resistivity of 0.028 264 ohm. mm2/mm at 200C as per IEC Standard. d)
Measurement of wire diameter, lay ratio, test procedure and testing of routine tests and acceptance tests have been included.
e)
Type tests have been included.
While revising this standard, it was decided to issue it in different parts covering different types of conductors. This part 'dealing with galvanized steel-reinforced aluminium conductors fonn Part 2 of the series. Other parts in this series are given below:
Part Part Part Part
I
3 4
5
Aluminium stranded conductors Aluminium.conductors, aluminized steel-reinforced Aluminium alloy stranded conductors Aluminium conductors, galvanized steel-reinforced for extra high voltage (400 kV and above).
In the preparation of this standard, assistance has been derived from the following: lEe 888: 1987 Zinc coated steel wires for stranded conductors. lEe 889: 1987 Hard drawn aluminium wire for overhead line conductors. lEe 1089: 1991 Round wire concentric lay overhead electrical stranded conductors.
as 215 : Part2 : 1970Specification for aluminium conductors and aluminium conductors. steel-reinforced for overhead power transmission: Part 2 Aluminium conductors, steel-reinforced. British Standards Instituuon.
The value of modulus of elasticity and coefficient of linear expansion are given in Annex B for information. For the purpose of deciding whether a particular requirement of this standard is complied with, the final value, observed or calculated, expressing the result of a test or analysis. shall be rounded off in accordance with IS 2 : 1960 'Rules for rounding off numerical values (revisedy , The numberof significant places retained In the rounded off value should be the same as that of the specified value in this standard.
IS 398 (Part Z) : 1996
Indian Standard ALUMINIUM CONDUCTORS FOR OVERHEAD TRANSMISSION PURPOSES - SPECIFICATION PART 2 ALUMINIUM CONDUCTORS, GALVANIZED STEEL-REINFORCED
(Third Revision) IECTION 1 GENERAL 1 SCOPE
1.3 DlretIIoa ef Lay
1.1 This standard (Part 2) covers the requirements and tests for aluminium conductors, galvanized steelreinforced used for overhead power transmission purposes.
The direction of lay is defined as right-hand or Jefthand. With right-hand lay, the wires conform to the direction of the central part of the letter Z when the conductor is held vertically. With left-hand lay, the wires conform to the direction of the central part of the letter S when the conductor is held vertically.
2 REFERENCES
3.4 Lay Ratio
2.1 The following Indian Standards are necessary adjuncts to this standard.
Ratio of the axial length of a complete turn of the helix formed by an individual wire in a stranded conductor to. the external diameter of the helix
IS No.
Title
209 : 1992
Zinc ingot (fourth revision)
4 PHYSICAL CONSTANTS FOR HARD-DRAWN ALUMINIUM
1778 : 1980
Reels and drums for bare wire (first
4.1 Resistivity
revision)
4826: 1979
Hot dipped galvanized coating on round steel wires (first revision)
The resistivity of aluminium depends upon its purity and physical condition. For the purpose of this standard, the maximum value permitted is 0.028 264 ohm mm2/m at 20°C and this value has been used for calculation of the maximum permissible values of resistance.
5484 : 1978
Be grade aluminium rod produced by continuous casting and rolling
NOTE- It IS not Intended to check the resisnvuy from the measured values of resistance.
7623 : 1993
Lithium base grease for industrial
1885 : Electrotechnicalvocabulary: Part 32 (Part 32) 1993 Electric cables (first revision)
purposes (second revision) 3 TERMINOLOGY
3.0 For the purpose of this standard, the following definitions, in addition to those given in IS 1885 (Part 32) : 1993 shall apply. 3.1 Aluminium Conductor, Galvanized SteelRelnforeed
Conductor consisting of seven or more aluminium and galvanizedsteel wires built up in concentriclayers. The centre wire or wires are of galvanized steel and the outer layer or layers of aluminium. 3.1 Diameter
The mean of two measurements at right angles taken at the same cross section.
4.2 Density At a temperature of 20 DC. the density of hard-drawn aluminum has been taken as 2.703 g1cm'.
4.3 Constant-Mass Temperature Coefficient Resistance
or
At a temperature of 20°C the constant-mass temperature coefficient of resistance of hard-drawn
aluminium, measured between two potential pomts rigidly fixed to the wire, the metal being allowed to expand freely. has been taken as 0.004 03 DC.
4.4 Coemcient of Linear Expansion The coefficient of linear expansion of hard-drawn aluminium at 0 °C has been taken as 23.0)( 10"1°C. This value holds good for all practical purposes over the range of temperature from 0 °C to the highest safe operating temperature.
IS 398 (Part 2) : 1996
SECTION 3 DIMENSIONS AND CONSTRUCTION
S PHYSICAL CONSTANTS FOR GALVANIZED STEEL WIRES 5.1 Density
8 STANDARD SIZES
At a temperature of 20°C, the density of galvanized
8.1 Wires
steel wire is to be taken as 7.80 g1cm" 8.1.1 Nominal Sizes 5.2 Coemcient at Linear Expansion
TIle aluminium and galvanized steel wires for the standard constructions covered by this standard shall have the diameter specified in Tables I and 2. The diameterof the galvanized steel wire shall be measured over the zinc coating.
In order to obtain uniformity in calculation, a value of 11.5x 10·"/oC may be taken as the value for the coefficient of linear expansion of galvanized steel wires used for the cores of steel-reinforced aluminium conductors.
8.2 Aluminium Conductors, Galvanized SteelReinforced
SECTION 2 MATERIALS 6
8.2.1 The sizes of stranded aluminium conductors, galvanized steel-reinforced shall be as given in Table 3.
MATERIAL
6.1 The conductorshall be constructed of hard-drawn aluminium and galvanized steel wires which have the mechanical and electrical properties specified in Tables 1 and 2.
8.2.2 The resistance shall be in accordance with Table 3. The mass (excluding the mass of grease, if applied) are given in Table 3 for information.
6.1.1 The Ee grade aluminium rods for use in the manufacture of aluminium wires shall conform to IS 5484: 1978.
9 T IN WIRES 9.1 The wires shall be drawn in continuous length, without ts, except those made in wire rod or before drawing operation.
6.1.2 Galvanized steel wire should be drawn from high carbon steel rods produced by either acid or base open hearth process, electric furnace or basic oxygen process. The mechanical properties of wire shall comply with the requirements given in Table 2. The chemical compositions of high carbon steel wire is given in Annex C for the purpose of guidance.
9.2 ts in Aluminium Stranded Wires
9.2.1 During stranding in aluminium wire no welds shall be made for the purposeof achieving the required conductor length.
6.2 The zinc used for galvanizing shall be electrolyte high grade zinc not less than 99.95 percent purity. It shall conform to and satisfy all the requirements of IS 209: 1992.
9.2.2 Conductor Containing Seven Wire.\'
ts in wires other than those permitted under 9.1 shall not be permitted in any wire of stranded conductor containing seven wires.
The coating on the galvanized steel wires may be applied by the hot process or the electrolytic process. When specified by the purchaser, neutral grease may be applied between the layers of wires.
9.2.3 Conductors Containing More Than Seven Wires
For stranded conductor containing more than seven wires, ts are permitted in wire broken during stranding provided such breaks are not associated with either inherently defective wire or with those of short lengths of aluminium,wires. ts shall be dressed smoothly with a diameter equal to that of parent wires and shall not be kinked. No two ts other than those in wires before stranding permitted under 9.1 occur at points in the stranded conductors nearer than 15 In.
6..3 When specified by the purchaser, neutral grease has to be applied as per one of the following cases: a)
Steel core only,
b) All conductor except outer layer,
c) All conductor including outer layer, and d) All conductorexcept outer surfaceof the wires in the outer layer.
9.2.4 ts shall be made by electric butt welding. electric butt cold upset welding or' cold pressure welding. These jomts shall be made in accordance with good commercial practice. Electric butt welding shall be annealed for approximately 250 mm on both sides of the welds,
NOTE- Luhium soap grease corresponding to Grade II of IS 7623 199:\ haVing mmunum drop point not less than 180"C is suitable for such application,
7 FREEDOM FROM DEFECTS 7.1 The wires used for standard conductor shall be smooth and free from imperfections, such as spills and splits.
While the ts specified are not required to meet the requirements of unted Wires, they shall
9.2.5
2
IS 398 (Part 2) : 19M be withstandinl a stress of not less than 75 MPa for
annealed electric butt wel4ed ts and not less than 130 MPafor cold pressure andelectric buttcold upset welded ts. The manufacturer shall demonstrate that the proposed welding method is capable of meeting the specified strength requirements.
9.3 Jolatl In J}alvaaIIed I
stele 'I
Wins
No ts of any kind shall be made in the finished coated steel wires. 10
STRANDlNG It
•
10.1 The wires used in the c~nstruction of a galvanizedsteel-reinforced aluminiumconductorshall, before stranding, satisfy all the relevant requirements of this standard.
to IS 1778 : 1981 be used) and marked with the following· a) Manufacturer's name, ,,) Size and type of conductor, c) Net weisht of conductor in kl, d) Gross weight of cOP"lIctor in kg, and e) Length Qf conductor in m.
11.1.1 The conductor may also be marked with the SIS Standard Mark.
12.1.2 The use of Ule Standard Mark is governed by the provisions of ~e Bureau 0/ Indian SltIndDrds Act, 1986 and t~e Rules and Regulations made thereunder. The details of conditions under whic~ a licence for the use of the Stan~ard Mark may be granted to manufacturers or producers may be obUli~ from the Bureau of Indian 'Standards.
lQ.Z The lay ratio of the different layers shall be within the limits given in Table '4. . ,. 10.3 The ratio of the nominal dj~meter of the aluminium wires to the nominal "diameter of the galvanized steel wires in any particular construction of galvanized steel-reinforced aluminium conductor, shall conform to the appropriate value given in Table 4. 10.4 In all constructions, the successive layers shall have opposite directions of lay, the outermost layer being right-handed. The wires in each layer shall be evenly and closely stranded.. 10.5 In conductors having multiple layers of aluminium wires. the lay ratio of any aluminium layer shall be not greater than the lay ratio of the aluminium layer immediately beneath it. 10.6 Steel wires shall be formed during stranding so that they remain intact when conductor is cut for jomting operation,
11 LENGTHS AND VARIAnONS IN LENGTHS 11.1 Unless otherwise agreed to between the purchaser and the manufacturer, galvanized steel reinforced aluminium conductor shall be supplied in the manufacturer's usual production lengths and with a permuted variation of ±5 percent jn the length of anyone conductor length.
Unless otherwise agreed to between the purchaser and the manufacturer, it shall be permissibleto supply not more than 10 percent of the lengths on anyone order In random lengths; none of them shall be shorter than one-third of the nominal length. PAp~ING
AND
~ARKING
12 PACKING AND MAltK1NG
1.2.J TIle conductorshall be woundon reels or drums
13 TESTS 13.1 Selection of Test Samples for Acceptance and Routine Test r
13.1.1 Samples of individual wires for tests specified in 13.2, 13.3.1, 13.4, 13.5, 13.6, 13.7 and 13.8 shall normally be taken by the manufacturer before stranding, from the outer ends of not less than 10 percent of wire coils.
13.1.1 Alternatively. if desired by the purchaser at the time of placing an order that the tests be made in the presence of his representative, samples of wire shall be taken from lengths of stranded conductors. Samptes shall then be obtained by cutting 1.2 m from the outer end of the finished conductor from not more than 10 percent of the finished reels or drums. If there is more than one length on any reel or drum, the sample shall be taken from the outer length. 13.1.3 Coils offered for inspection shall be divided (this may be done physically or on the basis of ~dentificalion numbers of the coils offered for supply) Into equal lots, the number of lots being equal to the number of samples to be selected. a fraction of a lot being counted as a complete lot. One sample coil shall be selected at random from each lot. 13.1.4 For the purposeof various tests, one specimen
means one sample of the conductor.
11.2 Random Leolths
SECTION 4
SECTION 5 TESTS
recommended that reels and drums conformmg
13.1.5 Type test shall be conducted at the works of the finn and if such facilities are not available, the same shall be got conducted at some test house agreed to between the purchaser and the supplier against each order in the presence of the purchaser. The supplier shall offer at least three drums of each size of conductor for selection of samples required for type test. Type test certificate of test house for same size of conductor carried out earlier shall be acceptable If agreed to between the purchaser and the supplier.
IS 398 (Part 2) : 19M 13.2 Mea.uremeDt 01 Diameter 01 ladlvldual AluminiulD Wires and Galvanized Steel Wires
NOTS - Portwoormen frIct... oc:aaNdduriD.lWildna. die filii fract. . would be c:aIIed • primary frIIdure aad die sublequent frac:hna would be called .,1eCOIIdarY frIcruJeI.
One sample cut from each of samples taken under 13.1.1 and 13.1.2 shall be measured using a micrometer having flat surface on both the anvil and the end of the spindle (0 be read with micrometer. The diameter in millimetre shall be average of three diameter measurements, each of which is the average of the maximum reading at a point taken near each end and in the centre of the sample.
When telted after strandin" the number of complete twists before fracture occun shan be not less dian 16 on a length equal to 100 times' the diameter of the wire. Tbe fracture shall show a smooth surface at right angles to the axis of the wire. 13.4.2 Elongation
The diameter of the wire shan be within the limit as specified in Tables 1 and 2.
T~st
The elongation of one specimen cut from each of the samples taken under 13.1.1 (I' 13.1.2 shall be determined. The specimen shall be straightened by hand and an original gauge length of 200 mm shall be marked on the wire. A tensile load shall be applied as described in 13.3.1 and the elongation shall be measured after the fractured ends have been fitted together. If the fracture occurs outside the gauge mark, or within 25 mm of either mark and the required elongation is not obtained, the test shall be disregarded and another test made.
13.3 BreaklDI Load Test
This test shall be made on both aluminium and galvanized steel wires. 13.3.1 The breaking load of one specimen cut from each of the sample taken under 13.1.1or 13.1.2shall be determined by means of a suitable tensile testing machine. The load shall be applied gradually and the rate of separation of thejaws of the testing machine shall be not less than 25 mm/min and not greater than 100 mm/min.
When tested before stranding, the elongation shall be not less than 4 percent. When tested after stranding, the elongation shall· be nbt less than 3.5 percent.
The ultimate breaking load of the specimens- shall be not less than the appropriate value specified in Tables I and 2.
NOTE - The sample has 10 either the torsion tell or elonption test, thai is, if the conductor is pOllina any of the two tests, the sample should be col1lidered II in,.
13.4 Ductility Test
13.5 Wrappinl Tad...
This test shall be made on galvanized steel wires only, by any of the procedures given in 13.4.1 and 13.4.1.
This test shall be made on both aluminium and galvanized steel wires.
13.4.1
13.5.1
Torsion Test
One specimen cut from each of the samples taken under 13.1.1 (I" 13.1.1 shall be gripped at its ends in two vices one of which shall be free to move longitudinally during the test. A small, tensile
Aluminium Wires
One specimen cut from each of the samples of aluminium wire taken under 13.1.1 and 1~.1.1 shall be wrapped round a wire of its own diameter to form a close helix of eight turns. Six turns shall then be unwrapped and again closelyt wrapped in the same direction as before. The wire shall not break.
load not exceeding 2 percent of the breaking load of the wire, shall be applied to the sample during testing. The specimen shall be twisted by causing one of the vices to revolve until fracture occurs and the number of twists shall be indicated by a counter or other suitable device. The rate of twisting shall not exceed 60 rev/min.
13.5.2 Galvanized Steel Wires
One specimen cut from each of the samples of galvanized steel wire taken under 13.1.1 cr 13.1.2 shall be wrapped round a mandrel of diameter equ~ to 4 times the wire diameter to fonn a close helix of 8 turns. Six turns shall then be unwrapped and againcloselywrapped in the same directionas before. The wire shall not break.
The test may be carriedout on gaugelength~f I SO Jl.lrn for all wire sizes when the number of twists, which the wire shall withstand, shall be direct ratio to the numbers specified for 100 times the diameter of the wires.
13.6
Whentested beforestranding, the numberof complete twists before fracture occurs shall be not less than 18 on a length equal to 100 times the diameter of the wire.
Resistance Test
This test shall be made on aluminium wires taken before stranding or after strandin•. NOTE - The resistance of individUli wi-a ....1be .uch dill the completed IlrudecI conductor meeII Ihe of the maximum rai.tance specified in Tlble 3 calcu"" by applyinl the relevant strandin. co...... liven 1ft Table ~.
_Ie'"
The primary fracture ~hall show. a smooth surface at ri,ht angles to the axis of the wire. Any secondary fracture shall be ignored. 4
IS 398 (Part 2) : 1996 The electrical resistance of one specimen of aluminium wire cut from each of the samples taken under 13.1.1 (l" 13.1.2 shall be measured at ambient temperature.
A sample of conductor of minimum S m length suitably clamped ~t either end. The load shall be increased at a steady rate up to rated ultimate breaking load and held for one minute. When so tested, the conductor shan not show any fracture. The applied load shall then be increased until the failing load is reached and the value recorded. A re-test up to a total of three tests, may be made if wire fracture occurs ~ithin one centimetre of the end fittings and the tensile strength falls below the specified breaking strength requirement.
The measured resistance shall be corrected to the value at 20 OC by means ~f the formula: I - X (T - 20) where resistance corrected at 20°C; resistance measured at T °C;
13.11
= constant-mass temperature coefficient of resistance. 0.004; and T
Stress-Strain Test
This test is applicable to conductors of nominal aluminum area 100 mm' and above.
= ambient temperature during measurement.
13.11.1 This test is contemplated only to collect the creep data of the conductor from the supplier. A sample of conductor of minimum 10 m length shall be suitably compressed with dead end clamps.
The resistance corrected at 20°C shall be not more than the maximum value specified in Table I.
13.7 Galvanizing Test
13.11.2 Test Set-up
This test shall be made on galvanized steel wires only.
13.11.2.1 The test sample shall be ed in a trough over its full length and the trough adjusted so that the conductor will not be lifted by more than 10 mm under tension. This shan be ascertained by actual measurement.
13.7.1 This test shalt be made on one specimen cut from each of the samples of the galvanized steel wires taken under 13.1.1
13.11.2.2 The distance between the clamp and the sleeve mouth shall be monitored with callipers during the test to ensure that. after the test. it does not change by more than I mm ± 0.1 from the value before the test.
13.8 Measurement of Lay RatlolDirection of Lay The lay ratio of each layer of the conductor shan be measured and checked as per the requirements specified in Table 4, 10.5 and lay direction shan be as per requirement of 10.4.
13.11.2.3 The conductor strain shall be evaluated from the measured displacements at the two ends of the gauge length of the sample. The gauge reference targets shall be attached to the clamps which lock the steel and aluminium wires together. Target plates may be used with dial gauges or displacement transducers and care shall be taken to position the plates perpendicular to the conductor. Twisting the conductor, lifting it and moving it from side-to-side by the maximum amounts expected during the test should introduce not more than 0.3 mm error in the reading.
13.9 Surface Condition Test This test is applicable to conductors of nominal aluminium area 100 mm! and above. A sample of the finished conductor having a minimum recommended length of S m with compression type dead end clamps compressed on both ends in such a manner as to permit the conductor to take its normal straight line shape, shall be subjected to a tension of SO percent of the ultimate breaking load of the conductor.
13.11.3 Test Loads for Complete Conductor The loading conditions for repeated stress-strain tests for complete conductor shall be as follows.
The surface shan not depart from its cylindrical shape nor shall the strands move relative to each other so as to get out of place or disturb the longitudinal smoothness of the conductor. The measured diameter at any' place shall be not less than the sum of the minimum specified diameter of the individual aluminium and stee,l strands as indicated in Tables I and 2 of this standard.
13.11.3.1 I kN load shall be applied initially to straighten the conductor. The load shall be removed after straightening and then the strain gauges are to be set at zero tension. 13.11.3.2 For non-continuous stress-strain data, the strain readings at I kN intervals at lower tensions and S kN intervals above 30 percent of ultimate breaking load shall be recorded.
13.10 Test lor Ultimate Breaking Load on
Stnaded Coaductor
13.11.3.3 The sample shall be reloaded to SOpercent of ultimate breaking load and held for I h. Reading
This test is applicable to conductors of nominal aluminium area 100 mm' and above.
s
IS _
(Part 2) :
1'" c) Stress-strain test (13.11),
are to be noted after " lO, 15, 30. 45 and 60 min durinl the hold period. The load shall be mleued after the hold period.
d) Mouuremcnt of diameter of individual aluminium ·and sJeel wires (l~.J~,
13.11.3.4 RelOldinl up to 70 percent of ultimate breakinl load be done and"eld for I h.lteadin,. are to be noJed after 5. lQ. '5, 30, 45 and 60 min",•. The load .hall then be released.
1hII'
-
e) Meuurement of lay ratio (13.'), f) Breakinl load of individual wires (13.3.1),
13.11.3.5 Reloadin. up to 85 percent of ultimate breakinlload shall be done and he'd for I h. Readin, are to be noted after " 10, 15, 30, 45 and 60 minutes and then load shall be released. I
,) Ductility lest (13.4),
13.11.3.6 Tension shall be applied a,ain and shall be increased uniforml~ .until the actual ~reaki~1
k) Oalvanizina test (13.7).
\
h) Wrapping test (13.5), j) Resistance test
T~st
Ltx.uls for
St~"
and
I
stren.th is reached. Simultaneous readlnls of tension and elongation shall be recorded up to 90 percent of ultimate breakins load at intervals described under 1.3.5. 13.1l.4
(t3.~),
14.2
Cor, Only
Accepta~e
Tests
a)
Measurement of diameter of individual aluminium and steel wires (s~e 13.2),
b)
Measurement of lay ratio (see 13.8),
The loading condition of repeated stress-strain tests for the steel core of ACSR shall be as follows.
c)
Breaking load of individual wires (see
13.11.4.1 The test shall consist of successive application of -load applied in a manner similar to that for the complete conductor at 30 percent, SO percent, 70 percent and 8S percent of ultimate breaking load.
d) Ductility test (see 13.4),
1~.3.1).
13.11.4.2 The steel core shall be loaded until the elongation at the beginnin, of each hold period corresponds to thatobtained on the complete conductor at 30 percent, SO percent, 70 percent and 8S percent of ultimate breaking load respectively.
Wrapping test (see 13.5),
t)
Resistance test (see 13.6), and
g)
Galvanizing test
(see 13.7).
14.3 Routine Test The routine tests shall be done same as acceptance tests and shall be carried out before and after stranding.
13.11.5 Stress-Strain Curves The design stress-strain curve shall be obtained by drawing a smooth curve through the 0.5 and 1 h points at 30 percent, SO percent and 70 percent and of ultimate breakinlload loadings. The stress-strain curves shall be submitted to the purchaser alongwith test results. The stress-straln data obtained during the test shall be corrected to the standard temperature that is 20 "C.
15 REJECTION AND RETESTS 15.1 Shouldanyone of the test pieces first selected
rail to the tests, three further samples from the same batch shall be selected, one of which shall be from the length from which the original test sample was taken. unless that length has been withdrawn by the supplier.
14 CLASSIFICATION OF TESTS
15.2 Should all of the three test pieces from these additional samples satisfy the requirements of the tests, the balch represented by these samples shan be deemed to comply with the standard. Should the test pieces from any of the three additional samples fail, the balch represented shall be deemed not to comply with the standard,
14.1 Type Tests "a) Surface condition test (see 13.9), b) Test for ultimate breaking load on stranded conductor (see 13.10),
I'
e)
Apphcable for conducton of DOlnlnw AlumlRluln Area 100 mm'
ond above
6
IS 398 (Part 2)
1996
SECTION' 6 TABLES Table 1 Aluminium Wires Used in the Construction of Aluminium Conducton, Galvanized Steel-Reinforced (Clauses 6.1, 8.1.1, 8.1.2.1, 13.2, 13.3.1., 13.5.1 and 13.6) Diameter
Cross Sectional Area of Nominal Diameter Wire
Mass
Resistance 3)
A
A Min
Mt~
(I)
(2)
(3)
(4)
(5)
(6)
mm
mm
mm
mm'
kg/kin
Ohrnsrkm
1.50 1.96
1.48 1.94· 2.09 2.56 2.97
1.52 1.98 2.13 2.62 3.03 3.21 3.38 3.54 3.57 3.84 4.13 4.17 4.77
1.767 3.017 3.497 5.269 7.069 7.942 8.814 9.621 9.787 11.34 13.14 13.40 17.50
4.78 8.16 9.45 14.24 19.11 21.47 23.82 26.01 26.45
16.432 9.561 8.237
rNominnl
2.11 2.59 3.00 3.18
s.as
3-.50
3.S3 3.80 4.09 4.13 4.72
s.is 3.32 3.46 3.49 3.76 4.05 4.09 4.67
Breaklnl Load, Mill
-c
",. Before Stranding (1)
35.51 36.21 47.30
kN
0.32 0.54 0.63 0.89 1.17 1.29 .1.43 1.55 1.57 1.80 2.08 2.13 2.78
4.079 3.626 3.265 3.006 2.954 2.545 2.194 2.151 . 1.650
30.65
(8)
kN
5.490
'-.
After Stranding
0.30 0.51
0.60 0.85 1.11 1.23 1.36 1.47 1.49 1.11 1.98 2.02 2.64
NOlE - The resistance has been calculated from the maximum value of resistivity and the cross sectional area based on the minimum diameter.
Table 2 Steel Wires Used in the Constructten of Aluminium Conductors, Galvanized Steel-Reinforced (Clauses 6.1, 8.1.1, 13.2 and A-3.2) Cross Sectional Area of Nominal Diameter Wire
Diameter
Nominal
r
Mi" /'\ (2)
(3)
mm
mm
I.~O
1.47
1.57 1.96 2.11 2.30 2.59
1.~4
1.53 1.60
l.OO
3.18 3.35 3.~3
4,l)9
1.92 2.07
2.2S. 2.54 2.94 3.12 3.28 146 4.01
Before (S)
Stranding (6)
kg/kin
kN
13.78 15.10
2.46 2.70 4.20 4.60 5.46 6.92 9.29 10.43 11.58 12.86 17.27
.......
(I)
2.()() 2.15 2.35 2.64 3.06 3.24 3.42
160 4.17
Min /\
,
MIIX
rnm
Breaking Load,
Ma.u
(4) mm' 1.767 1.936 3.017 3.497
23.S3 27.27 32.41 41.09 55.13 61.95 68.75 76.34 102.48
4.1~~
5.269 7.069 7.942 8.814 9.787 13.14
7
After Stranding (7) kN 2.34 2.57
3.99 4.37 5.19 6.57 8.83 9.91 11.00 12.22 16.4
IS 398 (Part 2) : 1996 Table 3 AllIIIlinIum CODdueton, Galvanized Steel-Relnlorced (Clmues 8.2.1.. 8.2.2 tnI A-3.2)
strandlal . .
NomIMI
SedIonaI Ara 01 AIumI"'m
Wire Dlmaeter A ,# Steel Aluminium
Alumlalum
ApproDute App.......... M_ DIameter
Calaalated
Resistance at 28°C, Max
Are."
(I)
(2)
(3)
(4)
(')
(6)
mm2
mm
mm
nun'
mm2
mm
(7) kglkm
10
611.50
I/l.SO
10.60
12.37
4.S0
43
Approximate -Calculated Brakln. Load
(8)
(9)
Ohmlkm
kN
2.780
3.97
1.618 1.394
6.74 7.61
18.10 20.98
21.12 24.48
S.88 6.33
73
1/4.09
31.61 S2.88 78.83
36.88 61.70 91.97
7.77 10.OS 12.27
128 214 319
0.928 9 0.552 4 0.371 2
11.12 11.25 26.91
614.72
7/1.57
105.0
III.~
300.59
7f2.S9 713.00
ISS.I 212.1
194.9 261.5
14.IS 18.13 21.00
394 726 974
0.279 2 0.187 I 0.139 0
32.41 67.34 89.67
713.18 7/3.53
404.1 428.9 528.5
425.2 484.5 597.0
26.88 28.62 31.77
1281 1621 1998
0.073 II 0.068 68 O.OSS 95
88.79 130.32 159.60
712.30
562.7
591.7
31.68
1781
0.052 31
120.16
18
611.96
1/1.96
20
612.11
112.11
30 50 80
612.59 613.35 614.09
112.59 113.35
100
ISO 200
3013.00
400 420 520
4213.50 5413.18 5414.13
7/1.96
560
42/4.13
NOTE - For the bais of calculation of this table I)
Total SectIonal
8S
(.w Annex A).
The sectional area is the sum of the cross-sectional areas of the relevant individual wires.
Table 4 Lay Ratios 01 Aluminium Conductors, Galvanized Steel-Reinforced (Clauses 10.2, 10.3 and 13.8) Number 01 Wires
'AJumiRi~
Sai"
1b,Io of Aluminium Wire
Lay Ratios for Steel Core
DIameter
(6 Wire
to Steel
Layer)
~
Outennost Layer
Lay Ratios for ~umlnlum Wire . . ...... Layer hnmediately Innermost Layer of
Beneath Outermost Layer
Wire DIameter~~~
Conductors with 3 Aluminium
~
Min
M,u
Min
MilX
Mit.
MtlX
Min
MtlX
(2)
(3)
(4)
(~)
(6)
(7)
(8)
(9)
(10)
(11)
6
1 7
1.0 3.0 1.0
10
6 30
13 13
10
14 14 14
1.8
13
10
13
10 10 10
16 16
1.0
28 28 28 28
16
10
17 17
(I)
7 7 7
42
S4
10
10 10
14
14
NOTE - For the purpose of calculation. the meen lay ratio shall be taken as the arithmetic mean of the relevant minimum and maximum values Jiven in this table.
Table 5 Standing Constants (Table I and Clauses 13.6. A-2. r, A-2.2 and A-2.3.1) Mass
Num.her of Wires In Conductor
,Aluminium (I)
/\
"
Steel (2)
r Al umlnlUln " (3)
A.
,
Strandin. Constant Electrical Resistance
Steel (4)
(~)
6
0
6.091
1.000
0.169 2
6
7
6.091
7.032
0.169 2
30
7
30.67
7.032
0.034 08
42
7
42.90
7.032
0.024 32
~4
7
55.23
7.012
0.018 94
8
IS 398 (Part 2) : 1996
ANNEX A (Table 3) NOTES ON CALCULATION OF RESISTANCE, MASS AND BREAKING LOAD A-I INCREASE IN LENGTH DUE TO
A-2.3 In calculating the stranding constants in Table 5. the mean lay ratio, that is, the arithmetic mean of the relevant minimum and maximum values in Table 4. has been assumed for each layer.
STRANDING A-I.I When straightened out, each wire in any particular layer of standard conductor, except the centtal wire. is longer than the stranded conductor by an amount depending on the lay ratio of that layer.
A-3 CALCULATED BREAKING LOAD OF CONDUCTOR A-3.t The breaking load of an aluminium conductorgalvanized steel, reinforced in of the sum of the strength of the individual component wires, may be taken to be as follows:
A-2 RESISTANCE AND MASS OF CONDUCTOR
A-2.1 In aluminiwn conductors, steel reinforced the conductivity of the steel core is neglected and the resistance of the conductor is calculated with reference to the resistance of the aluminium wires only. The resistance of any length of stranded conductor is the resistance of the same length of anyone aluminium wire multiplied by a constant, as set out in Table 5. A-2.2 The mass of each wire in a length of stranded conductor, except the central wire, will be greater than that of an equal length of straight wire by an amount depending on the lay ratio of the layer (see A-I.I). The total mass of any length of conductor is, therefore, obtained by multiplying the mass of an equal length of straight wire by the approximate constant set out in Table 5. The masses of the steel core and aluminium wires are calculated separately and added together.
a)
98 percent of the sum of the breaking loads of the aluminium wires plus 89 percent of the sum of the breaking loads of the galvanized steel wires, when taken from the stranded conductor and tested; or
b)
98 percent of the sum of the breaking loads of the aluminium wires plus 85 percent of the sum of the breakingloads of the galvanizedsteel wires, based on the breaking loads of the component wires before stranding, that is, in the coil.
A-3.2 The values of approximate breaking load of conductors. given in Table 3 have been calculated in accordance with (b) above and on the basis of the minimum breaking loads of the component wires given in Table I and 2.
ANNEX B (Foreword) MODULUS OF ELASTICITY AND COEmCIENT OF LINEAR EXPANSION
No. of Wires
r
/\
Aluminium
Steel
(1)
(2)
6
I 7 7 7 7
6 30 42 54
"
Final Modulus of
Coefficient of Linear
Elasticity (Practical) GN/m2
Expansion / °C
(3)
(4) 19. J x 10·" 19.8 x 10'(\
79 75 80 62
69
17.8
X
10-19
21.5 x 10'" 19.3 x 10.(\
NOTES 1 2
3 4
These values are given for infonnation only. Moduli values quoted may be regarded as being accurate to within ± 3 GN/m'. Moduli values quoted may be taken as applying to conductors stressed between 15 and 50 percent of the ultimate strength of the conductor. Coefficients of lineAl' expansion have been calculated from the final (pmctical) l1¥Xluli for the aluminium and steel components of the conductors and coefficientsof linear expansion of 23.0 x I()-6 nnd II 5 )( I~ I °C for aluminiuln and steel respectively.
ANNEX C (Clause 6.1.2) CHEMICAL COMPOSITION OF HIGH CARBON STEEL
Element
C·l The chemical composition of high carbon steel used in the manufacture of steel wire of ACSR
Manganese Phosphorus Sulphur Silicon
conductor is given below for guidance: Element
..Carbon
Percentage Composition 0.50 to 0.85 9
Percentage Compositior 0.50 to I. 10 Max to 0.035 Max 0.045 0.10 to 0.35
Bureau or lodlan Standards
BIS is a statutory institution established under the Bureau of Indian Standards Act, 1986 to promote harmonious development of the activities of standardization, marking and quality certification of goods and attending to connected matten in the country. Copyright
BIS has the copyright of all its publications. No part of these publications may be reproduced in any form without the prior permission in writing of DIS. This does not preclude the free use, in the course of implementing the standard, of necessary details, such as symbols and sizes, type or grade designations. Enquiries relating to copyright be addressed to the Director (Publications), BIS. Review of ladlan Standards
Amendments are issuedto standards as the need arises on the basisof comments. Standards are also reviewed periodically; a standard along with amendments is reaffirmed when such review indicates that no changes are needed; if the review indicates that changes are needed, it is taken up for revision. s of Indian Standards should ascertain that theyare in possessionof the latestamendments or edition by referring to the latest issueof 'BIS Catalogue' and 'Standards: Monthly Additions'. This Indian Standard has been developed from Doc: No. ET 37 (3842)
AmeDdmeDts Issued SiDce PubUcatioD
Amend No.
Date of Issue
TextAffected
BUREAU OF INDIAN STANDARDS
Headquarters : Telegrams : Manaksanstha (Common to all offices)
Manak Bhavan, 9 Bahadur Shah Zafar Marg, New Delhi 110 002 Telephones: 323 01 31, 323 33 75, 323 94 02
. Regional Offices :
Telephone 323 76 17 { 323 3841
Central
: Manak Bhavan, 9 Bahadur Shah Zafar Marg NEW DELHI 110002
Eastern
: 1/14 C.I.T. SchemeVII M, V. I. P. Road, Kankurgachi KOLKATA 700 054
337 84 99, 337 8S 61 { 337 8626, 337 91 20
Northern : SeQ 335-336,Sector 34-A, CHANDIGARH 160022
60 38 43 { 60202S
Southern : C.I.T. Campus,IV Cross Road,CHENNAI600 113
254 12 16, 254 1442 { 25425 19,25413 IS
Western
{ 832 92 95, 832 78 58 832 78 91, 832 78 92
: Manakalaya, E9 MIDC, Marol, Andheri (East) MUMDAI400 093
Branches
AHMEDABAD. BANGALORE. BHOPAL. BHUBANESHWAR. COIMBATORE. FARIDABAD. GHAZIABAD. GUWAHATI. liYDERABAD. JAIPlJR. KANPlIR. LUCKNOW. NAGPUR. NALAGARlt PA''fNA. PUNE. RAJKOT. rfHIRUVANANTHAPURAM. Reprography Unit) BIS, New Delhi, India
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