Thursday, December 10, 2009

CONDUCTOR

 

PART I: CONDUCTOR




1.         KIND OF CONDUCTOR

    1. Solid conductor
    2. Stranded circular conductor
    3. Stranded circular compacted conductor
    4. Sector shape conductor
    5. Flexible conductor


2.         HOW TO DESIGN A CONDUCTOR

DIAMETER


a.          Solid conductor

Table
1.1


Table
1.2
Rev.
0
Rev.
0
Ref.
SPLN 42-1:91 7 VE
Ref.
JIS C 3317:87
Nom sectional area (mm²)
Wire (mm)
Nom sectional area (mm²)
Wire (mm)
Nom diameter
Tolerance
Nom diameter
Tolerance
1.5
1.38
± 0.03
1.13
1.2
± 0.03
2.5
1.78
± 0.03
2.01
1.6
± 0.03
4
2.26
± 0.03
3.14
2.0
± 0.03
6
2.76

± 0.03
5.31
2.6
± 0.03
10
2.57
± 0.04
8.04
3.2
± 0.04

12.57
4.0
± 0.04
19.64
5.0
± 0.04


b.          Stranded circular conductor






D          : conductor diameter (mm)
k0          : diameter factor
d           : wire diameter (mm)

Table
003
Rev.
0
No of wire
No of layer
No of wire each layer
Diameter factor (k0)
7
1
1
1
19
2
6
3
37
3
12
5
61
4
18
7
91
5
24
9
127
6
30
11
169
7
36
13
217
9
42
15





Table
1.4
Rev.
0
Ref.
IEC 60502, IEC 228, SPLN 42 & VE
Cross section area (mm²)
No of wire
Wire diameter & tolerance (mm)
Conductor diameter & tolerance (mm)
1.5
7
0.52
±
0.01
1.56
±
0.03
2.5
7
0.67
±
0.02
2.01
±
0.06
4
7
0.85
±
0.02
2.55
±
0.06
6
7
1.04
±
0.03
3.12
±
0.09
10
7
1.35
±
0.03
4.05
±
0.09
16
7
1.71
±
0.03
5.13
±
0.09
25
7
2.14
±
0.03
6.42
±
0.09
35
7
2.52
±
0.03
7.56
±
0.09
50
19
1.83
±
0.03
9.15
±
0.15
70
19
2.17
±
0.03
10.85
±
0.15
95
19
2.52
±
0.03
12.60
±
0.15
120
37
2.03
±
0.03
14.21
±
0.21
150
37
2.25
±
0.03
15.75
±
0.21
185
37
2.52
±
0.03
17.64
±
0.21
240
61
2.25
±
0.03
20.25
±
0.27
300
61
2.52
±
0.03
22.68
±
0.27
400
61
2.89
±
0.03
26.01
±
0.27
500
61
3.25
±
0.04
29.25
±
0.28
630
91
3.00
±
0.03
33.00
±
0.33
800
91
3.35
±
0.04
35.75
±
0.44
1000
91
3.75
±
0.04
41.25
±
0.44



Table
1.5
Rev.
0
Ref.
JIS C 3317:87
Nom sectional area (mm²)
No of wire
Wire diameter & tolerance (mm)
Conductor diameter & tolerance (mm)
0.9
7
0.4
±
0.01
1.2
±
0.03
1.25
7
0.5
±
0.01
1.4
±
0.03
2.0
7
0.6
±
0.02
1.8
±
0.06
3.5
7
0.8
±
0.02
2.4
±
0.06
5.5
7
1.0
±
0.03
3.0
±
0.09
8.0
7
1.2
±
0.03
3.6
±
0.09
14
7
1.6
±
0.03
4.8
±
0.09
22
7
2.0
±
0.03
6.0
±
0.09
38
7
2.6
±
0.03
7.8
±
0.09
60
19
2.0
±
0.03
10.0
±
0.15
100
19
2.6
±
0.03
13.0
±
0.15
150
37
2.3
±
0.03
16.1
±
0.21
200
37
2.6
±
0.03
18.2
±
0.21
250
61
2.3
±
0.03
20.7
±
0.27
325
61
2.6
±
0.03
23.4
±
0.27
400
61
2.9
±
0.03
26.1
±
0.27
500
61
3.2
±
0.04
28.8
±
0.28




c.          Stranded circular compacted conductor







D             : conductor diameter (mm)
A             : nom cross sectional area (mm²)
f               : space factor
                                £ 38 mm² = 0.91
                                > 38 mm² = 0.88


Table
1.6 (COPPER)
Rev.
0
Ref.
IEC 60502, IEC 228, SPLN 42 & VE
Nom sectional area (mm²)
No of wire
Wire diameter & tolerance (mm)
Conductor diameter & tolerance (mm)
25
7
2.30
±
0.03
6.0
(5.6 ~ 6.5)
35
7
2.65
±
0.03
7.0
(6.6 ~ 7.5)
50
19
1.95
±
0.02
8.3
(7.7 ~ 8.6)
70
19
2.28
±
0.03
10.1
(9.3 ~ 10.2)
95
19
2.65
±
0.03
11.7
(11.0 ~ 12.0)
120
37
2.10
±
0.03
13.2
(12.5 ~ 13.5)
150
37
2.30
±
0.03
14.5
(13.9 ~ 15.0)
185
37
2.65
±
0.03
16.0
(15.5 ~ 16.8)
240
37
2.95
±
0.03
18.2
(17.8 ~ 19.2)
300
61
2.60
±
0.03
20.8
(20.0 ~ 21.6)
400
61
3.00
±
0.03
23.5
(22.9 ~ 24.6)
500
61
3.32
±
0.04
26.9
(25.7 ~ 27.6)
630
91
3.76
±
0.04
30.9
(29.3 ~ 32.5)
800
91
3.47
±
0.04
34.0
(32.3 ~ 35.7)
1000
91
3.88
±
0.04
38.0
(36.1 ~ 39.9)


Table
1.7 (ALUMINIUM)
Rev.
0
Ref.
IEC 60502, IEC 228, SPLN 42 & VE
Nom sectional area (mm²)
No of wire
Wire diameter & tolerance (mm)
Conductor diameter & tolerance (mm)
25
7
2.30
±
0.0250
6.0
(5.6 ~ 6.5)
35
7
2.65
±
0.0265
7.0
(6.6 ~ 7.5)
50
7
3.18
±
0.0318
8.3
(7.7 ~ 8.6)
70
19
2.30
±
0.0250
10.1
(9.3 ~ 10.2)
95
19
2.65
±
0.0265
11.7
(11.0 ~ 12.0)
120
19
3.00
±
0.0300
13.2
(12.5 ~ 13.5)
150
34
2.50
±
0.0250
14.5
(13.9 ~ 15.0)
185
34
2.78
±
0.0278
16.0
(15.5 ~ 16.8)
240
34
3.10
±
0.0310
18.0
(17.8 ~ 19.2)
300
55
2.78
±
0.0278
20.8
(20.0 ~ 21.6)
400
55
3.15
±
0.0315
23.5
(22.9 ~ 24.6)
500
55
3.50
±
0.0350
26.9
(25.7 ~ 27.6)
630
55
3.95
±
0.0395
30.9
(29.3 ~ 32.5)
800
84
3.62
±
0.0362
34.0
(32.3 ~ 35.7)
1000
84
4.04
±
0.0404
38.0
(36.1 ~ 39.9)


Table
1.8 (Nom Diameter for Copper and Aluminium Conductor)
Rev.
0
Ref.
NEMA WC*7:1998
Conductor size
Nom Diameter
Solid
Concentric Lay Stranded
Compact
Compressed
Class B
AWG
kcmil
mm²
mm
mm
mm
mm
22
0.182
0.324
0.643
-
-
-
20
1.02
0.519
0.813
-
-
-
19
1.29
0.653
0.912
-
-
-
18
1.62
0.823
1.02
-
-
-
17
2.05
1.04
1.15
-
-
-
16
2.58
1.31
1.29
-
-
-
15
3.26
1.65
1.45
-
1.598
1.646
14
4.11
2.08
1.63
-
1.788
1.847
13
5.18
2.63
1.83
-
2.012
2.073
12
6.53
3.31
2.05
-
2.256
2.324
11
8.23
4.17
2.30
-
2.535
2.616
10
10.38
5.261
2.588
-
2.845
2.946
9
13.09
6.631
2.906
-
3.200
3.302
8
16.51
8.367
3.264
3.404
3.581
3.708
7
20.82
10.55
3.665
-
4.013
4.166
6
26.24
13.30
4.115
4.293
4.521
4.674
5
33.09
16.77
4.620
-
5.080
5.232
4
41.74
21.15
5.189
5.410
5.715
5.893
3
52.62
26.67
5.827
6.045
6.401
6.604
2
66.36
33.62
6.543
6.807
7.188
7.417
1
83.69
42.41
7.348
7.595
8.179
8.433
1/0
105.6
53.49
8.252
8.534
9.169
9.449
2/0
133.1
67.43
9.266
9.550
10.312
10.617
3/0
167.8
85.01
10.40
10.744
11.582
11.938
4/0
211.6
107.2
11.68
12.065
13.005
13.411

250
126.7
12.70
13.208
14.173
14.605

300
152.0
13.91
14.478
15.519
16.002

350
177.3
15.03
15.646
16.789
17.297

400
202.7
16.07
16.739
17.932
18.491

450
228.0
17.04
17.780
19.025
19.609

500
253.4
17.96
18.694
20.041
20.650

550
278.7
-
19.685
21.057
21.717

600
304.0
-
20.650
21.996
22.682

650
329.4
-
21.463
22.885
23.570

700
354.7
-
22.276
23.749
24.486

750
380.0
-
23.063
24.587
25.349

800
405.4
-
23.825
25.400
26.162

900
456.0
-
25.375
26.949
27.788

1000
506.7
-
26.924
28.372
29.261

1100
557.4
-
-
29.794
30.709

1200
608.0
-
-
31.115
32.080

1250
633.4
-
-
31.775
32.741

1300
658.7
-
-
32.385
33.376

1400
709.4
-
-
33.604
34.671

1500
760.0
-
-
34.798
35.865

1600
810.7
-
-
35.941
37.059

1700
861.4
-
-
37.059
38.202

1750
886.7
-
-
37.592
38.760

1800
912.1
-
-
38.151
39.319

1900
962.7
-
-
39.167
40.386

2000
1013.4
-
-
40.208
41.453








Note: Class B usually used in VE, even NEMA have Class C and Class D.


d.          Sector shape conductor

Table
1.9 (Construction for Shape Conductor / Sector Shape)
Rev.
0
Ref.
BS 6622:85 & VE
Nom sectional area (mm²)
BS 6622
Nom dimension of conductor
VE
Nom dimension of conductor
Width
(mm)
Depth (mm)
Back radius (mm)
Corner radius (mm)
No of wire
Wire diameter (mm)
Width (mm)
Depth (mm)
Back radius (mm)
Corner radius (mm)
70
11.3
7.9
9.9
2.8
19
2.17
12.8
9.2
11.1
2.7
95
13.9
9.1
11.4
2.8
19
2.52
15.3
11.0
13.3
3.3
120
15.8
10.2
12.6
3.0
37
2.03
17.2
12.1
14.6
3.3
150
17.9
11.3
13.9
3.0
37
2.25
19.0
13.7
16.5
4.1
185
20.5
12.6
15.4
3.0
37
2.52
21.3
15.3
18.5
4.5
240
24.0
14.5
17.5
3.0
61
2.25
24.2
17.3
20.9
5.0
300
27.3
16.2
19.2
3.0
61
2.52
27.0
19.2
23.2
5.5



e.          Flexible conductor






     D        : conductor diameter (mm)
          : number of layer                                                         
d        : wire diameter (mm)
      n        : number of wire

Table
1.10
Rev.
0
Cross sectional area (mm²)
No of wire
Wire diameter & tolerance (mm)
Conductor diameter & tolerance (mm)
0.75
24
0.20
±
0.01
1.19
±
0.01
1
32
0.20
±
0.01
1.31
±
0.01
1.5
30
0.25
±
0.01
1.67
±
0.02
2.5
51
0.25
±
0.01
2.13
±
0.02
4
57
0.30
±
0.01
2.70
±
0.03
6
85
0.30
±
0.01
3.30
±
0.03
10
80
0.40
±
0.01
4.40
±
0.04
16
128
0.40
±
0.01
6.00
±
0.06
25
199
0.40
±
0.01
7.69
±
0.08
35
279
0.40
±
0.01
8.80
±
0.09
50
398
0.40
±
0.01
10.80
±
0.11
70
360
0.50
±
0.01
12.50
±
0.13
95
475
0.50
±
0.01
15.00
±
0.15
120
608
0.50
±
0.01
16.75
±
0.17
150
756
0.50
±
0.01
18.33
±
0.18
185
925
0.50
±
0.01
20.38
±
0.20
240
1221
0.50
±
0.01
23.45
±
0.23
300
1469
0.50
±
0.01
25.57
±
0.26
400
1958
0.50
±
0.01
29.44
±
0.29




WEIGHT


Table
1.11

Rev.
0

Aluminium / Aluminium Alloy
r = 2.7
Aluminium Clad
r = 6.59
Copper / Tinned Copper
r = 8.89
Steel
r = 7.8




a.          Single Wire (Solid Conductor)

Single core:       



                      
                       w1        : material weight for single core (kg/km)
r                    : material density
d            : wire diameter (mm)


b.          Stranded Circular Conductor and Flexible Conductor

Single core:       
                            

n         : number of wire
                                                k1       : stranded factor (table 012)
                                                w1      : material weight for single core (kg/km)

            
Table
1.12 (Stranded Factor –k1)
Rev.
0
No of wire
Stranded factor for fixed conductor
Stranded factor for flexible conductor
7
0.012
0.02
19
0.017
0.02
37
0.017
0.02
61
0.020
0.02
91
0.023
0.02
127
0.026
0.04
169
0.029
0.04
217
0.032
0.04


c.          Stranded Circular/Sector Compacted Conductor

Single core:       

                           
  A             : nom cross section area (mm²)

d.          Multi Cores Cable

Multi core:         

                           
  w2            : material weight for multi core (kg/km)


3.         ELECTRICITY IN CONDUCTOR

a.          Material Resistivity and Conductivity

Table
013

Table
014
Rev.
0
Rev.
0
Material
Resistivity (W.mm²/m)
Wire diameter (mm)
Conductivity (%)
Copper
0.017241
Uncoated Copper Wire
Aluminium
0.028264
0.10 £ d < 0.30
98
Aluminium Alloy
0.03284 (Type A)
0.30 £ d < 0.50
99
0.03253 (Type B)
0.50 £ d < 12.0
100
Steel
0.19157
Coated Copper Wire


0.10 £ d < 0.26
93


0.26 £ d < 0.50
94


0.50 £ d < 2.0
96


2.0 £ d < 8.0
98


Aluminium
61


Aluminium Alloy
52.5







b.          Conductor Resistance

JIS formula:       



R              : conductor resistance at 20°C (W/km)
C              : material conductivity at 20°C (%)
A             : nom cross section area (mm²)
k1             : stranding factor (see table 015)
k2             : assembling factor
k3             : process reduction factor for circular compact and sector conductor
k4             : max conductor resistance factor


IEC 228:78 & SPLN formula:






4.         SOME TROUBLE COULD BE OCCURRED IN CONDUCTOR AND THE PROCESSING

!        Visual or appearance checking have ever found rough and corrosion on conductor surface.

!        Conductor resistance more than max standard. It could be found from the dimension of wire or conductor, or from the resistivity of raw material (means the quality of material not good)

!        Water blocking powder excess on the conductor surface could be made a breakdown cable in high voltage test.
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