Engineering Specification
Electrical Networks
MESP 050100-04
TECHNICAL SPECIFICATION FOR
TRANSMISSION WIRE HARD-DRAWN COPPER 7/2.0 22mm2
Version: 1
Issued: November 2015
Owner: Engineering Division
Approved By:
Andrew Russack
Head of Engineering (Electrical)
PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION
ELECTRICAL NETWORKS SPECIFICATION
TRANSMISSION WIRE HARD-DRAWN COPPER 7/2.0 22mm2
MESP 050100-04
Version: 1 Effective from: 9th November 2015
L1-CHE-SPE-060
Approval
Amendment Record
Approval Date Version Description
09/11/2015 1 Initial issue
Approving Manager: Head of Engineering Electrical Approval Date: 09/11/2015 Next Review Date: 09/11/2018
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ELECTRICAL NETWORKS SPECIFICATION
TRANSMISSION WIRE HARD-DRAWN COPPER 7/2.0 22mm2
MESP 050100-04
Version: 1 Effective from: 9th November 2015
L1-CHE-SPE-060
Table of Contents
1. Purpose ............................................................................................................................. 4
2. Scope ................................................................................................................................ 4
3. Abbreviation ..................................................................................................................... 4
4. Definitions ......................................................................................................................... 4
5. References & Legislations ............................................................................................... 4
6. Material .............................................................................................................................. 5
7. Conductor Characteristics ............................................................................................... 5
8. Lay ..................................................................................................................................... 5
9. Dimensions ....................................................................................................................... 6
10. Pre-production Test Requirements ................................................................................. 6
11. Production Test Requirements ........................................................................................ 6
12. Quality Assurance ............................................................................................................ 6
13. Warranty ............................................................................................................................ 6
14. Packing ............................................................................................................................. 6
Approving Manager: Head of Engineering Electrical Approval Date: 09/11/2015 Next Review Date: 09/11/2018
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ELECTRICAL NETWORKS SPECIFICATION
TRANSMISSION WIRE HARD-DRAWN COPPER 7/2.0 22mm2
MESP 050100-04
Version: 1 Effective from: 9th November 2015
L1-CHE-SPE-060
1. Purpose
This document details the specification of 22 mm² hard-drawn copper transmission wire.
This is the metric equivalent to 0.0375 in2 (24 mm2) transmission wire currently being used
in the Metro Trains Melbourne 22 kV Transmission system.
2. Scope
The scope comprises the manufacture, testing and supply of 22 mm² hard-drawn copper
transmission wire.
3. Abbreviation
d Diameter of a strand (millimetres)
4. Definitions
Lay Ratio The ratio of the lay length to the external diameter of the
corresponding layer of wires
Right-hand Lay When the slope of the wires is in the direction of the central part of
the letter ‘Z’ when the conductor is held vertically
5. References & Legislations
AS 1391:2007 Metallic Materials Tensile Testing at Ambient Temperature
AS 1746:1991 Conductors - Bare Overhead - Hard-Drawn Copper
AS 2193:2005 Calibration and Classification of Force Measuring Systems
AS 2738:2000 Copper and Copper Alloys - Compositions and Designations of
Refinery Products, Wrought Products, Ingots and Castings
AS 3822 :2002 Test Methods for Bare Overhead Conductors
AS/NZS 1574:1996 Copper and Copper Alloys - Wire for Electrical Purposes
AS/NZS 2857:1996 Timber Drums for Insulated Electric Cables and Bare Conductors
AS/NZS ISO 9001 Quality Management Systems - Requirements.
Approving Manager: Head of Engineering Electrical Approval Date: 09/11/2015 Next Review Date: 09/11/2018
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ELECTRICAL NETWORKS SPECIFICATION
TRANSMISSION WIRE HARD-DRAWN COPPER 7/2.0 22mm2
MESP 050100-04
Version: 1 Effective from: 9th November 2015
L1-CHE-SPE-060
6. Material
a. The chemical composition of the material used for the solid conductor shall conform to
AS 2738:2000 alloy designation C11000 (Electrolytic tough pitch copper).
b. The maximum resistivity at 20°C is 0.017 77 µΩ.m (equivalent to a conductivity of 97%
IACS).
c. The minimum ultimate tensile strength is 440 MPa for the individual strands of the
hard-drawn copper wire. The ultimate tensile strength is given by 480-20d as per alloy
designation C11000 in AS 1574:1996. The calculated break load of the conductor is
92% of the sum of strengths of the individual strands before stranding.
d. The wire shall be clean, smooth and free from all defects
e. There shall be no joints in the wire.
f. The wire density at 20°C shall be 8,890 kg/m³ plus or minus 3%.
g. The coefficient of linear expansion is taken as 17x10-6 per °C.
h. Modulus of elasticity is taken as 112 GPa. This value is obtained after the initial stretch
of the wire following construction
7. Conductor Characteristics
The lay ratio affects the area, mass and resistance of conductors composed of stranded
wires. The following stranding constants are multiplied with the corresponding property of a
single strand to give the overall characteristic:
Stranding constants:
o Area: 6.942
o Mass: 7.058
Resistance: 0.144
Strand Dia. Cross-sectional Mass/km (kg) Calculated breaking DC resistance/km @
(mm) area (mm²) load (kN) 20°C (ohms)
2.00 22.0 197 8.9 0.814
1.98 (-1%) 21.55 193 8.72 0.83
8. Lay
Lay ratio and direction of the outer layer shall be:
6-wire layer: 13 min, 17 max. Right-hand lay
Approving Manager: Head of Engineering Electrical Approval Date: 09/11/2015 Next Review Date: 09/11/2018
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ELECTRICAL NETWORKS SPECIFICATION
TRANSMISSION WIRE HARD-DRAWN COPPER 7/2.0 22mm2
MESP 050100-04
Version: 1 Effective from: 9th November 2015
L1-CHE-SPE-060
9. Dimensions
Wire size and tolerances shall be in accordance with AS 1746:1991. For a 7/2.0 nominal
conductor of 22 mm² nominal cross-sectional area the overall wire diameter shall be 6.0
mm +/- 1%.
10. Pre-production Test Requirements
Mechanical, resistivity and suitable metallurgical tests shall be performed on samples of
wire joints produced using identical parameters to final production condition.
11. Production Test Requirements
For the purposes of this specification the metallurgical tests shall be in accordance with
AS/NZS 1574:1996. Mechanical and electrical tests shall be in accordance with AS
1746:1991 and AS 3822:2002.
12. Quality Assurance
The Supplier should meet the requirements of AS/NZS ISO 9001.
13. Warranty
The Supplier shall provide a ‘Certificate of Conformance’ together with a full test report as
stipulated in Production Test Requirements.
14. Packing
a) The transmission wire shall be wound without twists, or kinks, on drums of approved
design and of sufficient size to prevent sharp bends and shall be properly protected
against damage in transit.
b) Typically approved design is wooden drums lined with sisal-craft in general
accordance with AS 2857:1996 and the following Metro Trains Melbourne required
dimensions:
o Barrel diameter 500 mm minimum
o Overall diameter 1000 mm maximum
o Overall width 650 mm maximum
A mild steel reinforcing plate 400 mm2 by 6.4 mm thick shall be bolted to the middle of
each side of the drum with a minimum of 6 bolts. An 83 mm square hole shall be provided
in the drum and reinforcing plates to take a 76 mm spindle.
The free ends of the wire shall be suitably treated to prevent de-stranding. The inner end of
the conductor shall be passed through the drum flange to the outside and stapled securely.
The outer end of the conductor shall be secured to the inside of the drum flange with
staples and bent back on itself to prevent it from working loose.
c) Metro Trains Melbourne shall specify the length of the conductor on each drum.
d) The following information shall be legibly and indelibly marked on the flange of the
drums or a label securely attached thereto:
Approving Manager: Head of Engineering Electrical Approval Date: 09/11/2015 Next Review Date: 09/11/2018
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ELECTRICAL NETWORKS SPECIFICATION
TRANSMISSION WIRE HARD-DRAWN COPPER 7/2.0 22mm2
MESP 050100-04
Version: 1 Effective from: 9th November 2015
L1-CHE-SPE-060
(i) Supplier’s name
(ii) Supplier’s drum serial number
(iii) The conductor material and size (Hard-drawn copper, transmission wire 7/2.0,
22mm2)
(iv) Length of conductor
(v) Gross mass of conductor and drum
(vi) Handling or lifting instructions. The preferred method being by means of a
spindle through the spindle holes and a spreader to prevent damage to the
flanges
(vii) An arrow with the words 'ROLL THIS WAY' to indicate the direction in which
the drum should be rolled on the flanges
(viii) The Metro Trains Melbourne contract number, order number and specification
number
e) Alternative equivalent or superior packing system may be submitted to Metro Trains
Melbourne for consideration.
Approving Manager: Head of Engineering Electrical Approval Date: 09/11/2015 Next Review Date: 09/11/2018
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