CABLEWIRE 2008

NEW RANGE OF SPECIAL ALLOY CONDUCTORS: ADVANTAGES OVER

CONVENTIONAL ACSR AND AAAC CONDUCTORS

Mr G. L. Prasad
Sterlite Technologies Limited, Pune

INTRODUCTION
COMPLIANCE WITH STANDARDS
For several years, distribution and transmission
lines have been designed using aluminum Al-59 alloy conductor complies with the standard
conductors steel reinforced (ACSR) or in some SS4240814 and Al-59 alloy wires comply with
countries all aluminum alloy conductors (AAAC). standard SS4240813. These standards specify
Both types normally have a conductivity the limits for conductivity, strength and creep
calculated on the total area of 53-54% copper irrespective of the chemical composition. Other
(IACS). properties are similar to conventional AAAC
Since the mid-1970s the cost of producing conductors.
electric energy has grown rapidly, leading to an
increase in the cost of losses. An attempt to find Figure 1 (Original photo attached)
new conductor material producing fewer losses in
the network was started in Sweden at the
beginning of the 1970s and led in 1979 to the
release of a new conductor standard called Al-
59, where 59 stands for its conductivity (IACS).

HISTORY
At the beginning of 70’s AB Electrokopper in
Helinsburg developed an alloy with the trade
name DUCTALEX. It has a better conductivity
than ordinary alloys used for conductors but a
slightly lower mechanical strength.
This new conductor alloy was laboratory tested at
the Swedish state power board with respect to
creep, corrosion resistance, self-damping and
fatigue strength. All tests showed the same or, in
some aspects better than the ordinary alloys
need. Tests were made on actual distribution
lines starting in 1975.
As only satisfactory results were obtained, the
new alloy conductors were installed in 400 KV
lines. The measurement of sag after five years
showed a high degree of agreement with what
was predicted. Concurrent with all trials the
Swedish standardization committee worked out
and issued the standards SS4240813 for Al 59
wires and SS4240814 for Al 59 Alloy Conductors.

APPLICATION OF AL-59 ALLOY

CONDUCTORS
Al-59 Alloy Conductors are used in power
transmission and distribution lines for a wide
voltage range - low voltage to Ultra high Voltage.

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MATERIAL PROPERTIES
Sag after 10 Years - Mtrs
Size of the Conductor
Sag 10.33 9.3 9.83
Al-59 conductors ranging from Al-59 31Sq.mm
(7/2.38 mm) to Al-59 910 Sq.mm (61/4.36mm) Strength of the conductor - MPA
Strength of the wire UTS 270.02 264.57 240.86

For diameter less than 3.5 mm – 250 MPA

For diameter less than 4 mm – 240 MPA Mass of the conductor – Kg/Km

For diameter less than 4.5 mm – 230 MPa Mass 2004 1666 1640
Resistivity of the wire
Note: CCC calculation based on wind velocity of

Individual resistivity – 29.30 nΩm 1 m/sec and solar absorption coefficient is 0.6

Average resistivity -29.08 nΩm
Creep of the conductor Even though strength of the Al59 conductor is
Maximum conductor Creep at 23o Celcius, 40 % less compared to conventional AAAC. But strung
of rated tensile strength and 1500 Hours are as at the same tension as like conventional AAAC.
follows: The Important factor for choosing tension from

7 strands: 350 mm/Km the vibrating point of view is tension divided by
the conductor mass. This value is independent of

19 and 37 strands: 400 mm/Km Ultimate tensile strength.

61 strands: 450 mm/Km
ADVANTAGES OVER ACSR AND AAAC
COMPARISION WITH CONVENTIONAL ACSR
Higher current carrying capacity with lesser
AND AAAC cross sectional area
For comparison based on the current carrying
Higher power transfer capacity with lesser
capacity, Power transfer capacity, Strength of the cross sectional area
conductor and Sag calculated after 10 years from
the creep value, please refer Table 1.
Lower Sag
Table 1
Commercial benefits due to lower power loss
and higher power transfer capacity
PROPERTIES ACSR AAAC Al59
MOOSE MOOSE 593 REFERENCE OF USE OF AL-59 ALLOY
6201 Sq.mm CONDUCTORS
Alloy
Al-59 Alloy Conductors have been used
Cross sectional 597 604 593 extensively by Swedish Electricity, Swedish
Area Sq.mm Railways and Norway Electricity.
Current carrying capacity - Amperes
CONCLUSION
Operating Temp 838 “Power for all by the year 2012” is the vision of
65Deg.Cel the Ministry of Power, Government of India. The
Government of India’s Transmission Perspective
Operating Temp 1233 1307 Plan focuses on the creation of a ‘National Grid’
85 Deg.Cel in a phased manner by adding over 60,000 km of
Power Transfer Capacity - Mwh Transmission Network by 2012.

Twin Bundle 901 1326 1405 Such an integrated grid is envisaged to evacuate
additional 1, 00,000 MW by the year 2012 and
carry 60% of the power generated in the country.
Quad Bundle 1802 2652 2811 The existing inter-regional power transfer
capacity is 9,000 MW, which is to be further

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enhanced to 30,000 MW by 2012 through

creation of “Transmission Super Highways”.
On a global level, ABS Research, UK reports that
the global market for power transmission
conductors was valued at about US$12.3 Billion
in 2006 and has a CAGR of 7% from 2004
through 2006. ABS Research also anticipates a
stable demand growth in the global market from
2007 through 2010 at a CAGR of about 7%.
In view of development of new power
transmission and distribution grids by global
power incumbents, Al-59 Alloy Conductors would
have a special significance while designing
transmission line networks, as the properties of
these conductors enable superior power
evacuation while optimizing the cost of the entire
grid.

REFERENCE STANDARDS
Swedish Standards:
SS4240814: Aluminium alloy stranded
conductors for overhead lines – Al 59
Conductors.
SS4240813: Aluminium alloy wire for stranded
conductors for overhead lines – Al 59 Wires.

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