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Title:
PUBLIC
Unique Identifier:
TSP41-264
Document Type:
SPECIFICATION
Revision:
Effective date:
NOVEMBER 2006
Total pages:
13
Review date:
NOVEMBER 2009
CONTENTS
PAGE
1
2
3
4
Scope ................................................................................................................................................... 2
References .......................................................................................................................................... 2
Definitions ............................................................................................................................................ 2
Requirements ...................................................................................................................................... 3
4.1 General ......................................................................................................................................... 3
4.1.1 Standard drum sizes .............................................................................................................. 3
4.2 Fabrication .................................................................................................................................... 3
4.3 Matched set requirements ............................................................................................................ 4
4.4 Length ........................................................................................................................................... 4
5 Test Requirements ............................................................................................................................ 45
6 Packaging and marking requirements ................................................................................................ 5
6.1 Drums............................................................................................................................................ 5
6.2 Marking ....................................................................................................................................... 56
ANNEXURE A
Example of Technical Schedule A and B ................................................................... 7
ANNEXURE B
Typical drum sizes for overhead conductor ................................................................ 8
ANNEXURE C Conductor Strand Marking .......................................................................................... 9
ANNEXURE D Typical Characteristics of Proposed Greases .......................................................... 10
ANNEXURE E
Typical size wooden drum showing Eskom branded flange..................................... 11
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Unique Identifier:
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1 Scope
This specification covers the technical requirements for aluminium conductor with steel
reinforcement (ACSR), all aluminium alloy conductor (AAAC) and all aluminium conductor
(AAC) for use on Eskom's overhead power transmission lines.
2 References
The following documents contain provisions that, through reference in the text, constitute requirements
of this specification.
IEC 61089: 1991, Round wire concentric lay overhead electrical stranded conductors
IEC 60888: 1987, Zinc-coated steel wires for stranded conductors
IEC 60889: 1987, Hard-drawn aluminium wire for overhead line conductors
IEC 61394: 1997, Characteristics of greases for aluminium, aluminium alloy and steel bare
conductors
SANS10005: The Preservative treatment of timber
3 Definitions
3.1.1 All aluminium alloy conductors (AAAC) A conductor comprising helically wound aluminium
alloy wire.
3.1.2 All aluminium conductors (AAC): A conductor comprising helically wound hard drawn
aluminium wire.
3.1.3 Aluminium conductor, steel reinforced (ACSR): A conductor comprising hard-drawn
aluminium strands helically wound around steel reinforcing strands.
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4 Requirements
4.1 General
Nothing in this specification shall lessen the obligations of the supplier detailed in any other
specifications or documents forming part of the order.
The supplier shall be responsible for all aspects of quality, relating to manufacture, handling ,
packaging and transportation of his product.
Eskom will provide the technical detail for the required conductor as per Schedule A in ANNEXURE A.
The Supplier shall provide the details of the conductor offered in Schedule B. Any deviation from the
requirements shall be entered separately in a non-compliance statement.
4.2 Fabrication
4.2.1 Each wire shall be marked with two uniform longitudinal indentations, situated 180
opposed, along its entire length. A deviation angle of 5 to 15 degrees below 180 shall be
allowed to ensure proper contact between indent ring and wire. The dimension of the indent
mark shall be 0,3mm wide and the groove depth from 0,15mm down to 0,11 mm. The
marking rollers shall undergo periodic dimension checking to ensure that the marking groove
dimensions are within the specified limits (ANNEXURE C).The indentations shall be
performed after the wire drawing process, but before stranding. The indentations shall be
clearly visible and shall not affect the original wire characteristics, distort the wire roundness
or leave any sharp protrusions. The marking is protected by patent laws and shall therefore
be unique to and accepted by Eskom, prior to the first production run.
4.2.2 The location of all welds in individual aluminium wires shall be recorded. Copies of
these records shall be forwarded to Eskom at the time of conductor dispatch.
4.2.3 Not withstanding clause 5.5 of IEC 61089,
a) There shall be no joint in any individual wire of a steel core containing less than seven
wires.
b) Joints in individual wires of a steel core containing seven wires or more shall be
permitted, provided that
1) no two such joints are less than 15 m apart;
2) each joint is made by resistance butt welding and is protected against corrosion by
re-galvanizing; and
3) the diameter of the stranded core is not increased materially by the joint.
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4.2.4 The wire shall be so stranded that the conductor is essentially free from the tendency
to untwist or spring apart when cut.
4.2.5 The completed conductor shall be uniformly cylindrical and shall be capable of
withstanding normal handling during manufacturing, transportation, and installing without
being deformed from its cylindrical form in such a way as to increase corona losses and radio
interference.
4.2.6 When specified in the schedule of requirements, the core and the inner layers of
aluminium shall be greased with Castrol BJ20(see ANNEXURE D for typical characteristics)
or other approved grease, certified and tested in accordance with IEC 61394. The test
certificate of the grease to be used shall be supplied with the tender. The method of
application of the grease shall be as per IEC 61089 Case 4. Grease shall be uniformly
applied by a method approved by Eskom.
4.4 Length
The length of conductor on a drum shall not vary by more than +2 % and 0 % from the
nominal length.
The variation in length between conductors forming a matched set shall not exceed 20 m.
Only one continuous length of conductor per drum shall be permitted.
5 Test Requirements
5.1 Type, sample production and routine production tests shall be carried out by the supplier,
and shall be submitted to Eskom within 7 days.
5.2 A complete set of conductor type tests certificates, in accordance with IEC 61089, must
be submitted for at least one conductor per design type at tender stage. This set of type
tests will qualify the design range at tender stage. Before a conductor is supplied to
Eskom, a full set of type tests for the conductor must be submitted.
5.3 The tenderer shall provide Eskom with an estimate of the creep each conductor
can expect over a 20-year lifespan. The estimate must be given with full details of the
calculation thereof.
5.4 All conductors which deviate from the specification or these schedules will be rejected.
Should deviations from the specification be unavoidable, written acceptance of those
deviations shall be obtained from Eskom.
5.5 Test certificates showing results of production routine tests, shall be retained by the supplier for a
minimum of five years, whereas test certificates showing results of type tests shall be retained on
permanent record by the supplier, for Eskom's inspection.
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6.1.5
Wood lagging shall be used to protect the conductor. Four steel straps shall be used
to secure the lagging on steel drums. Wooden lagging should be uniformly spaced
with at most 10mm spacing between adjacent lagging. The battens shall be nailed to
the flanges of wooden drums and two steel band straps shall be provided around
each drum to prevent easy removal of the battens. The length of the nails used shall
be at least 10 mm less than the distance from the outside of the battens to the top of
the conductor on the drum. Care shall be taken to prevent the nails from protruding
through the surface of the flange.
6.1.6
The moisture content of wood used for the fabrication of drums and reels shall not
exceed 150g/kg(15%).
6.1.7
Wooden drums shall have been impregnated (by pressure or in a hot/cold open tank),
in accordance with SANS 10005, with a class C preservative or with chromated
copper arsenate or similar to prevent biological attack. The preservative used shall
not react with the metal of the conductor.
6.1.8
For wood prone to superficial mould, a mouldicide should be applied to prevent mould
attack.
6.1.9
6.2 Marking
Further to Clause 7.2 of IEC 61089 and Eskom's General Conditions of Purchase, the
following requirements shall also be met:
6.2.1 The drums for a matched set of conductors shall be marked:
1A and 1B for matched pairs;
1A, 1B and 1C for matched trips, etc.
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6.2.2
The actual measured length and nett mass of conductor shall be marked on each
drum in black stenciled lettering of 50mm height on the drum side.
6.2.3
Drums of greased conductor shall be marked "Greased with (the product name)".
6.2.4
All drum marking pertaining to a previous order shall be painted over or otherwise
satisfactorily obliterated.
6.2.5
All conductor drums destined for Eskom projects shall be branded with Eskom
signature (logo and logotype) on one of its flat sides (the flange).
The Eskom signature shall be printed in Eskom Blue or Black only on the whitecoloured background.
For metal drums and wooden drums, a portion of the flange surface shall be painted
in white to provide rectangular background on which the signature shall be printed in
Eskom Blue or Black only. The width (or height) of the white rectangular background
shall be three times the diameter of the circle part of the Eskom signature. The
printed Eskom signature shall appear central onto the white rectangular background
leaving a space equal to one signature circle on both front and back ends.
The Eskom logo printing shall be made by stencilling; taking care to complete
continuous character O in the name Eskom. Other equivalent techniques can be
used, once approved by Eskom.
The dimensions of complete Eskom signatures shall be a minimum length and width
(height) of 82 mm and 21 mm respectively. All other printing on the flange shall be
positioned so as to ensure a minimum clearance of one logo circle diameter away
from the Eskom signature. An example of a drum with the Eskom signature and
standard printing guidelines are shown in ANNEXURE E.
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ANNEXURE A
Item
Description
Clause
Schedule A
Schedule B
4
4.2.1
Requirements
Eskom conductor indentation markings as
required
4.2.6
Grease
Grease Trade name
Name of Manufacturer/Supplier
Product Classification
All layers greased accept the outside as
per IEC61089, Case 4
Specification and test certificate supplied
in accordance to IEC 61394
4.3
Matched Sets
Conform to requirements as per 4.3
6
6.1.1
6.2
Reference
Reference
Reference
NOTES: The bidder shall complete Schedule B for the type(s) of Conductor offered and compliance to schedule A. Motivation of
any deviation from the requirements shall be entered separately in a non-compliance statement.
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ANNEXURE B
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Type
Conductor
Diameter
ACSR
ACSR
(mm)
16,5
18,1
ACSR
21
ACSR
23,45
ACSR
28,62
ACSR
AAC
AAC
AAC
AAAC
AAAC
AAAC
AAAC
AAAC
AAAC
35,55
16,3
26,5
38,3
8,4
8,9
14,00
22,6
28,4
17,4
Bending Factor
Length Flange
Dia
Barrel
Dia
Width
(m)
2 000
1 500
2 000
2 500
3 000
1 500
3 000
1 500
3 000
1 500
2 750
2 000
1 000
2 000
1 500
2 500
2 500
1 000
2 000
2 000
2 000
(mm)
600
700
700
700
800
800
1 000
800
1 000
1 000
1 100
1 070
500
1 000
1 200
400
400
450
800
1 100
700
(mm)
900
900
900
800
900
900
900
800
900
900
1 050
1 220
650
800
900
500
650
650
900
800
800
(mm)
1 200
1 200
1 300
1 450
1 600
1 450
2 000
1 600
2 000
1 800
2 200
2 135
1 000
2 000
2 400
900
900
900
1 600
2 200
1 300
Flange
Thickness
(mm)
50
50
50
63
63
63
76
63
76
63
76
75
50
76
76
50
50
50
63
76
50
Spindle
Hole Dia
(mm)
92
92
92
92
92
92
92
92
92
92
92
92
92
92
92
92
92
92
92
92
92
ACSR 35D
AAC 30D
AAAC 30D
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ANNEXURE C
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ANNEXURE D
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Density at 20 C
0.878
Oil Separation(P121-4hrs@150 C)
0.15% Max
Drop Point C
>220C
265 - 295
Colour
Brown
100%
260
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ANNEXURE E
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Colour specifications:
The corporate signature may only appear in the Eskom corporate blue or in black
or in white.
Pantone 287C
100%C + 70%M + 0%Y + 10%K
To match colours, swatches must always be used. Previously printed material must
never be used for colour matching.
b)
There should always be a minimum clear area around the signature. This minimum is
equal to the full diameter of the logo (circle).
c)
The relationship between the logo and the logotype must always be followed exactly
as indicated in the graphic. The measurement between the logo (circle) and the
logotype (word Eskom) is twice the line-width of the circle.
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Revision Information
Rev
6
5
4
Notes
Paragraphs 4.1, 4.2.2 and 4.2.6 amended. Paragraph 4.4
changed. Par 5.2, 5.3, 6.1.6, 6.1.7, 6.1.8 and 6.2.5 added. 6.1.5
and 6.1.9, 6.2.2, 6.2.3, 6.2.4, Annexure A Amended. Annexures B,
C, D and E added. Renumber to TSP41-264.
Date
October 2006
November 2002
November 1995
March 1995
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