Conductor

CLASSIFICATION
&
ITS Manufacturing
TESTING Process

Prepared By: Julkarnain Ahemad.

L&T-QA/QC-DDIP-Sambalpur.
 Conductor

d
d
2d
d
Types of Aluminium Conductor
Types Aluminium Conductor

300A
480A
735A
800A
 All Aluminium Conductors (AAC)
This conductor is also known as aluminium stranded conductor. This conductor is manufactured from electrolytically refined (E.C.GRADE) aluminium,
having purity of minimum 99.5% of aluminium. All aluminium conductors are made up of one or more strands of aluminium wire depending on the end usage.
These conductors are also used extensively in costal because it has a very high degree of corrosion resistance

SIZE Current Carrying SIZE Current Carrying

AREA WEIGHT AREA WEIGHT
CODE NAME Al/St/Dia. Capacity at CODE NAME Al/St/Dia. Capacity at
(mm2) (Kg/Km) (mm2) (Kg/Km)
(mm.) 45oC* (Amp) (mm.) 45oC* (Amp)

1) Gnat 25 7/2.21 74 120 20) Clegg 95 7/4.17 262 276

2) Ant 50 7/3.10 145 189 21) Beetle 100 19/2.67 293 300

3) Wasp 100 7/4.39 290 295 22) Bee 130 7/4.90 361 320
4) Peony 150 19/3.18 415 363 23) Cricket 150 7/5.36 432 335
5) Spider 240 19/3.99 654 500
24) Hornet 150 19/3.25 434 350
6) Butterfly 300 19/4.65 888 700
25) Caterpillar 185 19/3.53 511 395
7) Rose 20 7/1.96 58 70
26) Chafer 200 19/3.78 587 425
8) Midge 22 7/2.06 64 90
9) Aphis 25 3/3.35 73 115 27) Cockroach 250 19/4.22 731 600

10) Weevil 30 3/3.66 87 145 28) Moth 350 19/5.00 1027 780

11) Iris 30 7/2.47 92 150 29) Drane 350 37/3.58 1027 770
12) Mosquito 35 7/2.59 101 155 30) Locust 400 19/5.36 1180 850
13) Ladybird 40 7/2.79 117 165
31) Centipede 400 37/3.78 1145 830
14) Poppy 50 7/3.12 146 193
32) Maybug 450 37/4.09 1340 900
15) Fly 60 7/3.40 174 212
33) Scorpion 500 37/4.27 1461 950
16) Aster 65 7/3.50 184 220
17)Bluebottle 70 7/3.66 202 232 34) Cicada 600 37/4.65 1732 1000

18) Earwing 75 7/3.78 215 245 35) Tarantula 750 37/5.23 2192 1200
19) Grasshopper 80 7/3.91 230 255
 All Aluminium Alloy Conductors (AAAC)
This conductor is made from aluminium-magnesium-silicon alloy of high electrical conductivity containing enough magnesium silicide to give it better mechanical properties after
treatment. These conductors are generally made out of aluminium alloy 6201. AAAC CONDUCTOR has a better corrosion resistance and better strength to weight ratio and improved
electrical conductivity than ACSR CONDUCTOR on equal diameter basis.AAAC exhibits excellent corrosion resistance specially in sea coast areas and in polluted industrial areas due to
absence of steel core

SIZE Current Carrying SIZE Current Carrying

WEIGHT WEIGHT
CODE NAME AREA ((mm2)) Al/St/Dia. Capacity at CODE NAME AREA ((mm2)) Al/St/Dia. Capacity at
(Kg/Km) (Kg/Km)
(mm.) 45oC* (Amp) (mm.) 45oC* (Amp)

1) Mole 15 3/2.50 40.15 65 11) Panther 232 19/3.94 636.63 520

12) Panther-up1 288 37/3.15 794.05 610

2) Squirrel 22 7/2.00 60.16 105

13) Panther-up2 346 37/3.45 952.56 720

3) Weasel 34 7/2.50 94.00 155
14) Kundah 400 37/3.71 1101.63 740
4) Rabbit 55 7/3.15 149.20 210
15) Zebra 465 37/4.00 1280.50 800
5) Raccoon 80 7/3.81 218.26 290
16) Zebra-up 525 61/3.31 1448.39 875
6) Dog 100 7/4.26 272.86 325
17) Moose 570 61/3.45 1573.71 900

7) Dog-up 125 19/2.89 342.51 360

18) Morkulla 604 61/3.55 1666.00 920

8) Coyote 148 19/3.15 406.91 400

19) Moose-up 642 61/3.66 1771.36 940

9) Wolf 173 19/3.40 474.02 460 20) Morkulla-up 695 61/3.81 1919.13 960

10) Wolf-up 200 19/3.66 549.40 480 21) Bersimis 767 61/4.00 2115.54 1000
 735A 800A

480A

300A
 Aluminium Conductors Steel Reinforced (ACSR)
We have firmly positioning ourselves as one of the overriding reinforced conductor aluminium steel manufacturers in India. Aluminium conductor steel reinforced is widely used in overhead
transmission line for primary and secondary distribution. It is manufactured of one or more aluminium as outer wire & wire stranded with zinc coated high strength steel core wire. Aluminium
conductor steel reinforced is manufactured as per BS-2l5 (part-II), ASTM B-232, DIN-48204 and IEC standard. It provides excellent mechanical strength without compromising the ampacity. These
type of conductors provide excellent design benefit for extra long spans, river crossing.

SIZE Current Carrying SIZE Current Carrying

CODE AREA WEIGHT CODE AREA WEIGHT
Al/St/Dia. Capacity at Al/St/Dia. Capacity at
NAME (mm2) (Kg/Km) NAME (mm2) (Kg/Km)
(mm.) 45oC* (Amp) (mm.) 45oC* (Amp)

1) Mole 10 6/1/1.50 43 90 19) Otter 80 6/1/4.22 339 310

20) Cat 95 6/1/4.50 386 340
2) Rose 18 6/1/1.96 72 100
21) Hare 100 6/1/4.72 425 360
3) Squirrel 20 6/1/2.11 85 130
22) Hyena 100 7/4.39 + 7/1.93 453 360
4) Weasel 30 6/1/2.59 128 170
23) Cougar 125 18/1/3.05 419 400
5) Rabbit 50 6/1/3.35 214 240
24) Leopard 125 6/5.28+7/1.75 493 410
6) Raccoon 80 6/1/4.09 320 300
25) Tiger 125 30/7/2.36 603 420
7) Dog 100 6/4.72+7/1.57 394 360 26) Dingo 150 18/1/3.35 506 450
8) Wolf 150 30/7/2.59 726 470 27) Caracal 175 18/1/3.61 587 560
9) Panther 200 30/7/3.00 974 560 28) Lynx 175 30/7/2.79 842 520

10) Zebra 420 54/7/3.18 1622 860 29) Jaguar 200 18/1/3.86 671 560

11) Moose 520 54/7/3.53 1998 980 30) Lion 230 30/7/3.18 1095 610
31) Bear 250 30/7/3.35 1214 650
12) Gopher 25 6/1/2.36 106 150
32) Goat 320 30/7/3.71 1489 730
13) Fox 35 6/1/2.79 149 190
33) Sheep 370 30/7/3.99 1723 800
14) Ferret 40 6/1/3.00 171 210
34) Antelope 370 54/7/2.97 1414 790
15) Mink 60 6/1/3.66 255 260
35) Bison 380 54/7/3.00 1443 800
16) Skunk 60 12/7/2.59 464 270
36) Deer 420 30/7/4.27 972 870
17) Beaver 70 6/1/3.99 303 290 37) Elk 475 30/7/4.50 2190 930
18) Horse 70 12/7/2.79 538 300 38) Camel 475 54/7/3.35 1799 920
Round shaped

Trapezoidal shaped
Soft aluminium

Up to 100°C to 180°C sag will not violate the limit

 Fiber reinforced composite conductor core Consist of
AL Oxide fiber which giving more strength to the
conductor & less expand due to high temperature

Up to 200°C sag will not violate the limit

It Can work up to 250°C sag will not violate the limit
Table Representing the Number of Strands, Diameter and Cross-Sectional view of Stranded Conductor
for Different no. of Layers
 Typical Manufacturing Process of AAC & ACSR Conductor

Stranding to actual size of

Aluminium ROD
conductor
RBD Process

RST Process
Drawn to Intermediate size Roll on to Drums (or) Coiled

Drawn to actual size Marking & Packing

Check as per STI of wire as

Inspection and Testing as per STI
required

Application of neutral grease

(whenever required by the Storage/Dispatch
customer)
 Typical Manufacturing Process Flow
Rod breakdown machine. Required size of strands after RBD Process

Check as per STI of

Aluminium ROD Drawn to Intermediate size Drawn to actual size
wire as required

Rigid Stranding Machine/Spooling process

 Rod breakdown Process.
 In this process elongating the thick wires or rod of metal to thin wires of required diameter.
the diameter of the initial rod or specimen reduces and length of the initial specimen increase
OR
 In this process a certain number of dies are there in machine in which rod are drawn through
the dies to obtained the required diameter. (Annealing and Dencer process is not required for AAC & ACSR Conductor)
Annealer:(This process required for all HTLS Cable)
 Annealing is the process of making the metal soft by heating it and then cooling suddenly.
The aluminium wire passed through many roller and cooling chamber and the coolant is sprayed
Over it inside the roller cabin and cooling cabin. After annealing, the wire passed through the Dancer.
Dancer:
 Dancer is used mainly to maintain uniform diameter throughout the length of
drawn wire. In dancer ,there are two roller ,which are maintained at particular distance vertically
and the wire is wound over them. These roller maintained at a distance ensure uniform tension
on the wire ,which turn result uniform diameter throughout the length of the drawn wire
Coiler:
 Coiler is used to coil the drawn wires in to a basket
It consist of a rotating capstan around which the drawn wires are wound to form the coil.
Spooler:
 Spooler serves the same purpose as that of the coiler
The main difference is that the coiler is used to fill the basket while spooler is used
to make small bobbins.
Click here to get the video of complete process
https://youtu.be/GkaPR6WqPFU
 Rigid Stranding Machine.

 The Rigid stranding machine is used for stranding Aluminium or copper wire, round sector
compact conductor.
OR
 The Rigid Stranding machine is used for stranding AL,CU wires, and conductors. Stranding
unilay and reverse concentric, round compressed ,compacted or sector shaped(straight or
spiralled) as per customer requirements.

Click here to get the video of complete process https://youtu.be/dWHPPrkxR8s

Inspection and Testing Process
 Mass of Zinc={(M1-M2)/m2}x1965xD
Inspection and Testing as per Approved MQP/GTP/Drawing
Inspection and Testing Process

Wrap Test-A test consist of Coiling the wire a given number of times, over a mandrel of its
own diameter and uncoiling ,The usual test is to wrap eight turns and unwrap seven.
The wire must not facture and the surface must remain free of imperfection.
Torsion Test: An Electromechanical or hydraulic power testing machine can be used for torsion testing.
Small diameter specimens such as wire, bar or machined samples can be twisted to determined
shear modulus, peak torque, and breaking strength.

Adhesion Test: To determine if the paint or coating will adhere properly to the substrates to
which they are applied.
Elongation Test: To determine the ductility of material as determined
by a tension test.it is the increase in the gauge length of a test
specimen after facture divided by its original gauge length, Higher
elongation means higher ductility.

Click the the bellow link to get the video of testing process
https://youtu.be/XuG9zL4SBGk
Mass of Zinc Test: To determine weight (mass) of coating for comparison with specific requirement
A coating of Zinc on iron or steel articles provides against corrosion. Mass of Zinc={(M1-M2)/m2}x1965xD
Click the bellow link to get the video of testing process
https://youtu.be/H9YuxQRuz-w

Preece test: To deter mine the uniformity of galvanized coating by multiple times dipping the
sample in to cupper sulphate solution for 1mnt after that removed it from solution & washed by running water
and freed from the loosely precipitated copper by light rubbing repeat the same process 3times to observed cupper
deposition on exposed iron.Zn+Cuso4=Cu+Znso4(Solution of cupper sulphate of a specified concentration 1.27mole
This concentration usually defined by its specific gravity 1.186 at 18C.)

Click the bellow link to get the video of testing process

https://youtu.be/qOmJjTMRNy8