New Final AL 59 Conductor Specification 05.12.18 Docx 1
New Final AL 59 Conductor Specification 05.12.18 Docx 1
New Final AL 59 Conductor Specification 05.12.18 Docx 1
/2018/10
TECHNICAL SPECIFICATION
FOR
AL-59 CONDUCTOR
FOR
DISTRIBUTION SYSTEM
IN
MSEDCL
MMC: MSC II / AL59 cod./2018/10
INDEX
Clause No. Contents
AL-59 CONDUCTOR
1. SCOPE
2. SERVICE CONDITIONS
3. SYSTEM DETAILS
4. APPLICABLE STANDARDS
5. GENERAL TECHNICAL REQUIREMENT
6. PRINCIPAL PARAMETERS
7. PHYSICAL CONSTANT OF MATERIAL
8. RESISTIVITY
9. DENSITY
10 CONSTANT – MASS TEMPERATURE CO- EFFFICIENT (α):
11. CO-EFFFICIENT OF LINEAR EXPANSION:
12. MATERIAL
13. WIRE SIZES
14. JOINTS IN WIRE
15. STRANDING
16. STANDARD LENGHT
17. TEST AND STANDARDS
18. TESTING EXPENSES
19. ADDITIONAL TESTS
20 TEST REPORTS
21 INSPECTION
22 TEST FACILITIES
23 PACKING FOR CONDUCTOR
24 MARKING
MMC: MSC II / AL59 cod./2018/10
1. SCOPE:
a. Specification covers the design, manufacture, testing at works and supply of AL 59
conductor conforming SS 4240813, SS 4240814 ( swedish standard) ,IS : 398(Part IV/V)
1994, IS : 1778 before dispatch, packing and delivery FOR destination ..The system shall be A.C.
3 phase, 3 wires, 33/22/11 kV, 50 HZ.
2. SERVICE CONDITIONS:
The AL59 conductor to be supplied against this specification shall be suitable for satisfactory
continuous operation under the following tropical conditions.
2.1 Maximum ambient temperature (Degree C) 50
2.2 Maximum temperature in shade (Degree C) 45
2.3 Minimum Temperature (Degree C) 3.5
2.4 Relative Humidity (percent) 10 to 95
2.5 Maximum Annual rain fall (mm) 1450
2.6 Maximum wind pressure (kg/sq.m) 150
2.7 Maximum altitude above mean sea level ( Meter) 1000
2.8 Isoceranic level (days per year) 50
2.9 Siesmic level (Horizontal Acceleration) 0.3 g
Moderately hot and humid tropical climate conductive to rust and fungus growth ….
3. SYSTEM DETAILS:
AL59 conductor are meant for erection of 33,22,11kV lines with relevant parameters as under:-
Sr. Particulars Details
No..
1. System Voltage 33 22 11
2. Maximum Voltage 36 24 12
3. Frequency 50 Hz 50 Hz 50 Hz
4. Lightening impulse withstand voltage(Dry and wet) 70/170 50/125 28/75
(peak) (peak) (peak)
5. Power frequency withstand voltage (wet) 70 50 28
6. Short circuit level in 3 sec .kA 25 25 25
4. APPLICABLE STANDARDS:
a. SS :4240813( swedish standard) for AL59 conductors.
b. SS :4240814( swedish standard) for AL59 conductors.
c. IS : 398(Part IV/V) 1994.
MMC: MSC II / AL59 cod./2018/10
d. IS : 1778.
The AL-59 should be as per SS 4240814 and its latest amendments. The material offered
shall be of the best quality and workmanship. The AL-59 shall have accurate chemical
composition of alloy so as to offer excellent corrosion resistance, better strength of weight
ratio and improved conductivity. The solution treatment shall be done in a very sophisticated
and advanced technology furnace with automatic quenching system.
8. RESISTIVITY :
The resistivity of AL-59 depends upon its purity and its physical condition. For the
purpose of this specification the maximum value of the wire strand Per kilometer at
20deg.C shall be as per SS4240813 and this value shall be used for calculation of
maximum permissible value of resistance.
9. DENSITY :
At a temperature of 20deg. C, the density of hard drawn aluminum alloy has been
taken as 2.70 g/cm3.
MMC: MSC II / AL59 cod./2018/10
The Co-efficient of linear expansion of hard drawn aluminum alloy has been taken as
23x10-6/0C. This value holds good for all practical purposes over the range of
temperatures from zero degree centigrade to highest safe operating temperature.
12. MATERIAL:
a)Aluminium alloy:
The conductor shall be manufactured from alloy grade aluminium rods suitably hard-
drawn on wire drawing machines. The mechanical and electrical properties of
aluminium alloy wire shall comply with the requirements given SS4240813 relevant
standard.
b) Freedom from Defects:
The wires shall be smooth and free from all imperfections such as spills, splits, slag
inclusion, die marks, scratches, fittings, blow-holes, projections, looseness,
overlapping of strands, chipping of aluminium alloy layers etc. and all such other
defects , which may hamper the mechanical and electrical properties of the
conductor. Special care should be taken to keep away dirt, grit etc. during stranding.
13. WIRE SIZES:
a) Nominal size :
The aluminium alloy for the stranded conductor covered by this standard shall
have diameters specified in clause 6.0.
b) Tolerances on normal size:
A tolerance of +/-1% is permitted on the nominal diameter of Conductor.
NOTE : In order to maintain the circularity of the wires the tolerance allowed
shall apply to both the measurements at right angles taken at the same cross-
section as per clause 2.2 of IS:398 (Part IV) Third Revision and
SS4240813/4240814.
14. JOINTS IN WIRE:
No joints shall be permitted in the aluminium alloy wires in the outermost layer of the
AL59 conductor. Joints in the inner layers are permitted, in addition to those made in
the base rod or wire before final drawing, but no two such joints shall be less than 15
meters apart in the complete stranded conductor. Such joints shall be made by cold
pressure butt-welding.
NOTE : Joints are not permitted in the outermost layer of the conductor in order to
ensure a smooth conductor finish and reduce radio interference levels and corona
losses on the extra high voltage lines
MMC: MSC II / AL59 cod./2018/10
15. STRANDING:
The lay ratio of the different layers shall be within the limits given in the table below.
NOTE: For the purpose of calculation, the mean lay ratio shall be taken as the
arithmetic mean of the relevant minimum and maximum values given in this table.
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.
In conductors having multiple layers of aluminium alloy wires, the lay ratio of any
aluminium alloy layer shall not be greater than the lay ratio of the aluminium alloy
layer immediately beneath it.
16. STANDARD LENGHT:
The Standard Length of the conductor shall be 1500 meters. A tolerance of +/- 5% on
the standard length offered by the Bidder shall be permitted. All lengths outside this
limit of tolerance shall be treated as random lengths.
Random lengths will be accepted provided no length is less than 70% of the standard
length and total quantity of such random lengths shall not be more than 10% of the
quantity ordered. When one number random length has been manufactured at any
time, five (5) more individual lengths, each equivalent to the above random length
with a tolerance of +/- 5% shall also be manufactured and all the above six random
lengths shall be despatched in the same shipment. At any point, the cumulative
quantity supplied including such random lengths shall not be more than 12.5% of the
total cumulative quantity supplied including such random lengths. However, the last
20% of the quantity ordered shall be supplied only in standard lengths as specified.
Bidder shall also indicate the maximum single length, above the standard length, he
can manufacture in the guaranteed technical particulars of offer. This is required for
special stretches like river crossing etc. The MSEDCL representative reserves the
right to place orders for the above lengths on the same terms and conditions
applicable for the standard lengths during tendency of the contract.
NOTE: “The Guaranteed Technical Particulars for the Conductor being supplied
shall be provided with the Bid as specified in the Technical Specification. The
Bids without the Guaranteed Technical Particulars shall be treated as Non-
Responsive.” The GTPs shall also include creep calculations.
MMC: MSC II / AL59 cod./2018/10
The Type Test, Acceptance Tests and routine tests during manufacture, shall be
carried out on the conductor as per the IS-398 (part-4) of 1996 and latest revision of
SS 4240813/SS 4240814.
The conductor offered should be type tested for all the type tests. Test reports should
not be more than seven years old reckoned from the date of bid opening in respect of
all the testes carried out from Govt./Govt. approved reputed test house or at
accredited laboratory (accredited based on ISO/IEC guide 25/17025 or EN 45001 by
the National Accreditation body of the country where laboratory is located) or
witnessed by the representative (s) of MSEDCL or Utility shall be submitted
alongwith the Bid.
In the event of non-availability of test report or any discrepancy in the test
report (i.e., any test report not applicable due to any design / material/manufacturing
process change including substitution of components or due to non-compliance with
the requirement stipulated in the Technical Specification) the tests shall be conducted
by the Supplier at no extra cost to the Employer/ Purchaser.
Acceptance tests shall mean those tests which are to be carried out on samples taken
from each lot offered for pre-despatch inspection, for the purpose of acceptance of
that lot.
Routine tests shall mean those tests, which are to be carried out on each strand/
spool/length of the conductor to check requirements which are likely to vary during
production.
Tests during manufacture shall mean those tests, which are to be carried out during
the process of manufacture and end inspection by the manufacture to ensure the
desired quality of the end product to be supplied by him.
Samples for individual wires for tests shall be taken before stranding from not less
than ten percent of the spools in the case of aluminium alloy wires. If samples are
taken after stranding, they shall be obtained by cutting 1.2 metres from the outer end
of the finished conductor from not more than ten percent of the finished reels.
The standards and norms to which these tests will be carried out are listed against
them. Where a particular test is a specific requirement of this specification, the
norms and procedures of the test shall be as specified in Annexure-II or as
mutually agreed to between the Bidder and the Purchaser in the Quality
Assurance Program.
For all acceptance tests, the acceptance values shall be the values guaranteed by the
bidder in the guaranteed technical particulars of his proposal or the acceptance value
specified in this specification, whichever is more stringent for that particular test.
18. TESTING EXPENSES:
The entire cost of testing for the acceptance and routine tests and tests during
manufacture specified herein shall be treated as included in the quoted unit price
except for the expenses of the inspector/ MSEDCL representative.
19. ADDITIONAL TESTS:
The MSEDCL representative reserves the right of having at his own expenses any
other test (s) of reasonable nature carried out at Manufacturer’s premises, at site, or
MMC: MSC II / AL59 cod./2018/10
in any other place in addition to the aforesaid type, acceptance and routine tests to
satisfy himself that materials comply with the specifications.
20. TEST REPORTS :
a) Record of routine test reports shall be maintained by the manufacturer at his works
for periodic inspection by the MSEDCL representative.
b) Test certificates of tests during manufacture shall be maintained by the
manufacturer. These shall be produced for verification as and when desired by the
MSEDCL representative
21. INSPECTION :
The MSEDCL representative shall at all times be entitled to have access to the works
and all places of manufacture, where conductor shall be manufactured and
representative shall have full facilities for unrestricted inspection of the manufacturer
works, raw materials and process of manufacture for conducting necessary tests as
detailed herein.
The manufacturer shall keep the MSEDCL representative informed in advance of the
time of starting and of the progress of manufacture of conductor in its various stages
so that arrangements can be made for inspection.
The supplier shall give 15 days advance intimation to enable the purchaser to depute
his representative for witnessing acceptance and routine tests.
No material shall be dispatched from its point of manufacture before it has been
satisfactorily inspected and tested, unless the inspection is waived off by the
MSEDCL representative in writing. In the later case also the conductor shall be
dispatched only after satisfactory testing for all tests specified herein have been
completed.
At least 5% of the total number of drums subject to minimum of two in any lot put up
for inspection, shall be selected at random to ascertain the length of conductor by
the following method:
"At the works of the manufacturer of the conductor, the conductor shall be
transferred from one drum to another at the same time measuring its length with the
help of a graduated pulley & Cyclometer. The difference in the average length thus
obtained and as declared by the Bidder in the packing list shall be applied to all
the drums if the conductor is found short during checking."
At least 10% of the total drums in any lot put up for inspection, shall
be selected at random to conduct the “Acceptance Tests” by the inspector. The
acceptance Tests shall be carried out on all the samples drawn from the sampling
drums selected as above. If any sample drawn does not pass the Acceptance tests, the
drum from which the sample is drawn will be rejected and another drum from the
same lot shall be selected at random to repeat the “Acceptance Tests”. If the second
sample also fails in the same Test, the entire lot offered for Inspection will be
rejected.
The acceptance of any quantity of material shall in no way relieve the manufacturer
of any of his responsibilities for meeting all requirements of the specification, and
shall not prevent subsequent rejection if such material is later found to be defective.
All wooden components shall be manufactured out of seasoned soft wood free free
from defects that may materially weaken the component parts of the drums.
Preservative treatment for anti-termite/anti fungus (Aldrime / Aldruse) shall be
applied to the entire drum with preservatives of a quality, which is not harmful to the
conductor.
The flanges shall be of two ply construction with each ply at right angles to the
adjacent ply and nailed together. The nails shall be driven from the inside face flange,
punched and then clenched on the outer face. The thickness of each ply shall not very
by more than 3 mm from that indicated in the figure. There shall be at least 3 nails
per plank of ply with maximum nail spacing of 75 mm. Where a slot is cut in the
flange to receive the inner end of the conductor, the entrance shall be in line with the
periphery of the barrel.
The wooden battens used for making the barrel of the conductor shall be segmental
type. These shall be nailed to the barrel supports with at least two nails. The battens
shall be closely butted and shall provide a round barrel with smooth external surface.
The edges of the battens shall be rounded or chamfered to avoid damage to the
conductor.
Barrel studs shall be used for the construction of drums. The flanges shall be holed
MMC: MSC II / AL59 cod./2018/10
and the barrel supports slotted to receive them. The barrel studs shall be threaded
over a length on either end, sufficient to accommodate washers, spindle plates and
nuts for fixing flanges at the required spacing.
Normally, the nuts on the studs shall stand protruded of the flanges. All the nails used
on the inner surface of the flanges and the drum barrel shall be counter sunk. The
ends of barrel shall generally be flushed with the top of the nuts.
The inner check of the flanges and drum barrel surface shall be painted with bitumen
based paint.
Before reeling, cardboard or double corrugated or thick bitumen zed waterproof
bamboo paper or woven HDPE sheet shall be secured to the drum barrel and inside of
flanges or the drum by means of a suitable commercial adhesive material. The
paper should be dried before use. After reeling the conductor, the exposed surface
of the outer layer of conductor shall be wrapped with thin polythene sheet across the
flanges to preserve the conductor from dirt, grit and damage during transportation
and handling and also to prevent ingress of rain water during storage/transport.
A minimum space of 75 mm for conductor shall be provided between the inner
surface of the external protective lagging and outer layer of the conductor.
Each batten shall be securely nailed across grains as far as possible to the flange,
edges with at least 2 nails per end. The length of the nails shall not be less than twice
the thickness of the battens. The nails shall not protrude above the general surface
and shall not have exposed sharp, edges or allow the battens to be released due to
corrosion.
The nuts on the barrel studs shall be tack welded on the one side in order to fully
secure them. On the second end, a spring washer shall be used.
Outside the protective lagging, there shall be minimum of two binder consisting of
hoop iron/ galvanised steel wire. Each protective lagging shall have two recesses to
accommodate the binders.
The conductor ends shall be properly sealed on the side of one of the flanges to avoid
loosening of the conductor layers during transit and handling.
24. MARKING :
Each drum shall have the following information stenciled on it in indelible ink alongwith
other essential data:
a) Contract / Award letter number.
b) Name and address of consignee.
c) Manufacturer’s name and address.
d) Drum number.
e) Size of conductor.
f) Length of conductor in meters.
g) Gross weight of drum with conductor.
h) Gross weight of drum without lagging.
i) Weight of empty drum with lagging.
j) Barrel diameter at three locations and an arrow marking at the location of measuremen
k) Arrow marking for unwinding.
MMC: MSC II / AL59 cod./2018/10
The individual strands shall be dimensionally checked to ensure that they conform
to the requirements to this specification.
ANNEXURE-II
3. Number of strands
4. Diameter of stands (AL-59)
(a) Nominal mm
(b) Maximum mm
(c ) Minimum mm
5. Overall diameter of conductor mm
6. Cross sectional area of
a) whole conductor Sq. mm
b) each stand Sq. mm
7. Purity of aluminium rods – min %
8. Number of stands
(a) Centre No.
(b) 7 wire Aluminium layer No.
© 19 wire Aluminium layer No.
9. Weight of
a) whole conductor Kg/km
b) aluminium alloy strand (at nominal dia) Kg/km
10. Calculated D.C. resistance at 200 deg.C
a) whole conductor ohm/km
b) aluminium alloy strand ohm/km
MMC: MSC II / AL59 cod./2018/10