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INTRODUCTION
Conductor:
The coil from a electric heater gets hot and conducts electricity well. A conductor is something
which allows electricity to flow through.
• An example of a conductor is:
– Scissors
– Paper clip
– Aluminum foil
– Iron
– Steel
– Copper
In all good conductors electric current flows through them without resistance.
Example: Electricity flows through the coil in the power line coils without resistance and easily
When it comes to the flow of electric current, all materials fall into three categories:
• insulators
• conductors
• resistors
Insulator
• Any material that does not allow electric current to pass through it
Insulators like plastic and rubber are used as a covering for electric wires.
This makes electric wires safer to handle because the insulator protects you from the
current.
Conductor
Resistor
A material or a device that allows some current to pass but converts some of the current to
another form of energy.
An electrical conductor is a substance in which electrical charge carriers, usually
electrons, move easily from atom to atom with the application of voltage. Conductivity, in
general, is the capacity to transmit something, such as electricity or heat.
Pure elemental silver is the best electrical conductor encountered in everyday life.
Copper, steel, gold, aluminum, and brass are also good conductors. In electrical and electronic
systems, all conductors comprise solid metals molded into wires or etched onto circuit boards.
Some liquids are good electrical conductors. Mercury is an excellent example. A
saturated salt-water solution acts as a fair conductor. Gases are normally poor conductors
because the atoms are too far apart to allow a free exchange of electrons. However, if a sample of
gas contains a significant number of ions, it can act as a fair conductor.
A substance that does not conduct electricity is called an insulator or dielectric material.
Common examples include most gases, porcelain, glass, plastic, and distilled water. A material
that conducts fairly well, but not very well, is known as a resistor. The most common example is
a combination of carbon and clay, mixed together in a specific ratio to produce a constant and
predictable opposition to electric current.
Substances called semiconductors act as good conductors under some conditions and
poor conductors under other conditions. Silicon, germanium, and various metal oxides are
examples of semiconductor materials. In a semico
CONDUCTORS MATERIALS
Conduction materials include metals, electrolytes, superconductors, semiconductors,
plasmas and some nonmetallic conductors such as graphite and Conductive polymers.
Copper has a high conductivity. Annealed copper is the international standard to which
all other electrical conductors are compared. The main grade of copper used for electrical
applications, such as building wire, motor windings, cables and busbars, is electrolytic-tough
pitch (ETP) copper (CW004A or ASTM designation C100140). This copper has an electrical
conductivity of at least 101% IACS (International Annealed Copper Standard).
If high conductivity copper must be welded or brazed or used in a reducing atmosphere,
then oxygen-free high conductivity copper (CW008A or ASTM designation C10100) may be
used.[2] Because of its ease of connection by soldering or clamping, copper is still the most
common choice for most light-gauge wires.
Silver is more 'conductive' than copper, but due to cost it is not practical in most cases.
However, it is used in specialized equipment, such as satellites, and as a thin plating to mitigate
skin effect losses at high frequencies.
Aluminum wire, which has 61% of the conductivity of copper, has been used in building
wiring for its lower cost. By weight, aluminum has higher conductivity than copper, but it has
properties that cause problems when used for building wiring. It can form a resistive oxide
within connections that makes wiring terminals heat. Aluminum can "creep", slowly deforming
under load, eventually causing device connections to loosen, and also has a different coefficient
of thermal expansion compared to materials used for connections. This accelerates the loosening
of connections. These effects can be avoided by using wiring devices approved for use with
aluminum.
Aluminum wires used for low voltage distribution, such as buried cables and service
drops, require use of compatible connectors and installation methods to prevent heating at joints.
Aluminum is also the most common metal used in high-voltage transmission lines, in
combination with steel as structural reinforcement.
Anodized aluminum surfaces are not conductive. This affects the design of electrical
enclosures that require the enclosure to be electrically connected. Organic compounds such as
octane, which has 8 carbon atoms and 18 hydrogen atoms, cannot conduct electricity. Oils are
hydrocarbons, since carbon has the property of tetracovalency and forms covalent bonds with
other elements such as hydrogen, since it does not lose or gain electrons, thus does not form ions.
Covalent bonds are simply the sharing of electrons. Hence, there is no separation of ions when
electricity is passed through it. So the liquid (oil or any organic compound) cannot conduct
electricity.
While pure water is not an electrical conductor, even a small portion of impurities, such as salt,
can rapidly transform it into a conductor.
TYPES OF CONDUCTORS:
There is no unique process by which all transmission and/or distribution lines are
designed. It is clear, however, that all major cost components of line design depend upon the
conductor electrical and mechanical parameters.
There are four major types of overhead conductors used for electrical transmission and
distribution.
 AAC - All Aluminum Conductor
 AAAC - All Aluminum Alloy Conductor
 ACSR - Aluminum Conductor Steel Reinforced
 ACAR - Aluminum Conductor Aluminum-Alloy Reinforced
The various combinations and modifications of these conductor types provide a wide
variety of possible conductor designs.
AAC - All Aluminum Conductor, sometimes referred to as ASC, Aluminum Stranded
Conductor, is made up of one or more strands of 1350 Alloy Aluminum in the hard drawn H19
temper. 1350 Aluminum Alloy, previously known as EC grade or electrical conductor grade
aluminum, has a minimum conductivity of 61.2% IACS. Because of its relatively poor strength-
to-weight ratio, AAC has had limited use in transmission lines and rural distribution because of
the long spans utilized. However, AAC has seen extensive use in urban areas where spans are
usually short but high conductivity is required. The excellent corrosion resistance of aluminum
has made AAC a conductor of choice in coastal areas.
ACSR - Aluminum Conductor Steel Reinforced, a standard of the electrical utility
industry since the early 1900's, consists of a solid or stranded steel core surrounded by one or
more layers of strands of 1350 aluminum. Historically, the amount of steel used to obtain higher
strength soon increased to a substantial portion of the cross-section of the ACSR, but more
recently, as conductors have become larger, the trend has been to less steel content. To meet
varying requirements, ACSR is available in a wide range of steel content - from 7% by weight
for the 36/1 stranding to 40% for the 30/7 stranding. Early designs of ACSR such as 6/1, 30/7,
30/19, 54/19 and 54/7 strandings featured high steel content, 26% to 40%, with emphasis on
strength perhaps due to fears of vibration fatigue problems. Today, for larger-than-AWG sizes,
the most used strandings are 18/1, 45/7, 72/7, and 84/19, comprising a range of steel content
from 11% to 18%. For the moderately higher strength 54/19, 54/7, and 26/7 strandings, the steel
content is 26%, 26% and 31%, respectively. The high-strength ACSR 8/1, 12/7 and 16/19
strandings, are used mostly for overhead ground wires, extra long spans, river crossings, etc.
The inner-core wires of ACSR may be of zinc coated (galvanized) steel, available in
standard weight Class A coating or heavier coatings of Class B or Class C. Class B coatings are
about twice the thickness of Class A, and Class C coatings about three times as thick as Class A.
The inner cores may also be of aluminum coated (aluminized) steel or aluminum clad steel. The
latter produces a conductor designated as ACSR/AW in which the aluminum cladding comprises
25% of the area of the wire, with a minimum coating thickness of 10% of the overall radius. The
reinforcing wires may be in a central core or distributed throughout the cable. Galvanized or
aluminized coats are thin, and are applied to reduce corrosion of the steel wires. The conductivity
of these thin coated core wires is about 8% IACS. The apparent conductivity of ACSR/AW
reinforcement wire is 20.3% IACS.
ACSR STRANDINGS
6201 "AAAC" - A high strength Aluminum-Magnesium-Silicon Alloy Cable was
developed to replace the high strength 6/1 ACSR conductors. Originally called AAAC, this alloy
conductor offers excellent electrical characteristics with a conductivity of 52.5% IACS, excellent
sag-tension characteristics and superior corrosion resistance to that of ACSR. The temper of
6201 is normally T81.
6201 aluminum alloy conductors are typically sold as O.D. equivalents for 6/1 and 26/7 ACSR
constructions. The O.D. equivalent 6201 conductors have approximately the same ampacity and
strength as their ACSR counterparts with a much improved strength-to-weight ratio. 6201
conductors also exhibit substantially better electrical loss characteristics than their equivalent
single layer ACSR constructions. However, the thermal coefficient of expansion is greater than
that of ACSR. As with AAC conductors, the maximum short circuit temperature of 6201 must be
kept below 340°C to prevent dangerous conductor annealing.
As compared to ACSR, AAAC's ligher weight, comparable strength and current carrying
capacity, lower electrical losses and superior corrosion resistance have given this conductor wide
acceptance as a distribution conductor. It has found limited use, however, as a transmission
conductor.
ACAR - (Aluminum Conductor-Aluminum Alloy Reinforced) - ACAR combines 1350 and 6201
aluminum alloy strands to provide a transmission conductor with an excellent balance of
electrical and mechanical properties. This conductor consists of one or more layers of 1350-H19
aluminum strands helically wrapped over one or more 6201-T81 aluminum alloy wires. The core
may consist of one or more 6201 strands. The primary advantage of the ACAR conductor lies in
the fact that all strands are interchangeable between EC and 6201, thereby permitting the design
of a conductor with an optimum balance between mechanical and electrical characteristics. In
effect, ACAR is a composite aluminum-aluminum alloy conductor which is designed for each
application to optimize properties. Inverse ACAR conductors are also available with the harder
6201 aluminum alloy wires being on the outer surface of the conductor and the 1350 aluminum
making up the heart of the conductor.
Typical Stranding For Concentric-Lay-Stranded ACAR Conductors
AACSR - (6201 Aluminum Alloy Conductor Steel Reinforced) - Is an ACSR with the 1350
aluminum wires replaced by 6201-T81 aluminum alloy wires. The high tensile strength of the
6201-T81 wires combined with the high strength of steel provides an exceptionally high strength
conductor with good conductivity. AACSR conductors have approximately 40% to 60% more
strength than comparable standard ACSR conductors of equivalent stranding, with only an 8-
10% decrease in conductivity. AACSR is available with all core types specified for use with
standard ACSR.
SSAC - (Steel Supported Aluminum Cable) - SSAC conductor was designed for use as a
replacement conductor in upgrading existing transmission and distribution lines with minimum
capital outlay. The premise of design is higher conductor operating temperature without
detrimental annealing of the aluminum in standard ACSR causing a loss of strength in the
aluminum. SSAC conductor is an aluminum-steel composite conductor resembling standard
ACSR in appearance, stranding and overall diameter. This is the extent of their similarities
however. SSAC uses 1350-0 (fully annealed) aluminum strands with 63.0% conductivity rather
than the traditional 1350-H19 hard drawn aluminum used in standard ACSR which possesses
61.2% IACS conductivity. The steel core may be made of conventional or extra high strength
steel core wire. Compared to an equal size ACSR, SSAC has a lower resistance, lower breaking
strength, lower creep elongation and lower elastic modulus. SSAC can be operated at
temperatures as high as 250°C without loss of strength and can be strung at higher unloaded
percentage tensions because of its good self damping characteristics.
SSAC has seen limited use in the United States. Even though SSAC has better conductivity, a
higher operating temperature and improved damping characteristics when compared to
conventional ACSR, it has a lower breaking strength, typically yielding greater initial and final
sags. It is, however, a good conductor to consider for line upgrades if the calculated present
worth of electrical losses shows a savings over line conversion cost.
Expanded ACSR - This conductor is designed to be used where large diameter single
conductors are required to reduce the electrical stress gradient at the surface of the conductor to
provide corona-free operation. Expanded ACSR is used when a single conductor rather than a
conductor bundle is used at EHV voltage levels. Expanded ACSR is specially fabricated to have
a larger outside diameter than could be achieved using the circular mil area of aluminum
required. Expansion is achieved by the use of oversized wires widely spaced in successive wire
layers near the core. Expansion has also been achieved by the use of extruded metal shapes and
various rope, paper or jute fillers. Expanded conductors can offer improved sag characteristics as
well as efficient design. Because of the precise fabrication techniques required to manufacture
expanded conductors and a history of installation problems, these conductors have not been
widely used.
Smooth Body Conductors:
Some cables are designed to produce a smooth outer surface and reduce overall diameter. This
smaller diameter reduces the ice and wind loading encountered during severe weather, thereby
reducing the pole/tower loading or allowing longer design spans. Smooth body conductors are of
two types - compact conductors or trapezoidal shaped wire compact conductors, i.e., TW
conductors.
Compact Conductors - Compact overhead conductors are typiclly available in both AAC and
ACSR with diameter reductions ranging from 8% to 11%. AAC conductors are available in a
size range of #8 AWG through 1000 kcmil with standard stranding as listed in ASTM. Compact
ACSR conductors are available only in sizes #6 AWG through 336.4 kcmil in constructions with
a single steel core wire.
Compact conductors are manufactured by passing the stranded cable through powerful
compacting rolls or a compacting die. The strands are deformed, to the degree they loose their
circularity, partially filling the interstrand voids and the outer surface of the conductor becomes a
relatively smooth cylinder. The resulting reduction in overall diameter not only reduces the ice
and wind loading characteristics of the conductor but also reduces the stress gradient at the
conductor surface.
150% / 200% ACSR - The terms 150% and 200% ACSR refer to a family of single layer (6/1)
constructions of ACSR that have 150% and 200% of the strength of the equivalent construction
standard ACSR while exhibiting approximately the same overall diameter. The 150% and 200%
smooth body ACSR was developed to provide a conductor with a substantial increase in ultimate
strength as compared to standard 6/1 ACSR constructions. This is accomplished by using a
larger steel core wire and drastically flattening the aluminum strands to create a smooth
cylindrical conductor surface.
150% and 200% smooth body ACSR is fabricated by passing the composite stranded cable
through a die or rolls so designed to flatten the aluminum strands and fill the interstices which
exist in conventional stranded ACSR. This brings about a reduction in overall cable diameter
which means a lower ice and wind load and greater strength to loaded weight ratio.
These conductors were primarily designed for use on rural distribution lines. The reduced
diameter and extra high strength provide substantial design and operational advantages for the
longer spans of a rural distribution line serving sparcely populated areas subject to severe cold
weather conditions.
Trapezoidal Shaped Wire Conductors - Shaped wire compact conductors made from
trapezoidal (TW) shaped wires is a relatively new conductor design. These conductors can be
provided in AAC, AAAC and ACSR constructions and are designated as types AAC/TW,
AAAC/TW and ACSR/TW.
Conventional conductor designs have traditionally used round wires. The use of technology to
design and produce trapezoidal wires (TW) provides conductor designers with an alternative to
conventional round strand conductor designs. The use of trapezoidal wire designs yields compact
conductors with less void area and a reduced outside diameter.
With conventional ACSR strandings, the number of aluminum and steel strands uniquely define
the ratio of steel area to aluminum area. For example, all 26/7 ACSR constructions have the
same ratio of steel area to aluminum area of about 16%. However, with TW strands the number
of aluminum and steel strands do not necessarily define a unique steel to aluminum ratio.
Therefore the designation of "type" has replaced the stranding designation to more accurately
identify TW conductors. For example a 795 kcmil-26/7 ACSR "Drake" has a TW counterpart
designated 795 kcmil Type 16, ACSR/TW. The aluminum area and steel area of both conductors
are identical. The use of TW shaped aluminum strands will cause the ACSR/TW to have a
smaller diameter.
The following table relates ACSR/TW Type Number with standard conventional ACSR
stranding.
Comparison of ACSR/TW with equivalent stranding of ACSR
ACSR/TW TYPE CONVENTIONAL ACSR
Number* Stranding*
5 42/7
7 45/7
8 84/19
10 22/7
13 54/7
13 54/19
15 26/7
Comparison of ACSR/TW with equivalent stranding of ACSR ACSR/TW type conventional
ACSR Number* Stranding 5 42/7 7 45/7 8 84/19 10 22/7 13 54/7 13 54/19 15 26/7
An alternate design concept is to specify ACSR/TW conductors with equivalent overall
diameters to conventional ACSR constructions. In this case, the diameter is matched to that of
the standard ACSR while maintaining the same ratio of steel to aluminum by area. Since the
aluminum area is increased, the steel area must be increased to maintain the proper area ratio.
If a reduced diameter TW construction is selected, the diameter is reduced by
approximately 10% thereby reducing the design ice and wind loading on the conductor. If an
equal diameter TW construction is selected, the aluminum area is increased by approximately
20% - 25% providing a decrease in AC resistance of 15% - 20% and increasing the current
carrying capacity 8% to 10%.
The use of trapezoidal wires provides a more compact conductor design with mechanical
properties at least equal to that of conventional ACSR. Since ACSR/TW designs have the same
steel-to-aluminum ratios as their equivalent ACSR constructions, stress-strain and creep data
developed for conventional strandings of ACSR can be used to predict sag and tension design
data for ACSR/TW conductor constructions.
TW conductor installation requires no special tools, equipment or training.
ACSR TRAPEZOIDAL SHAPED WIRE CONDUCTOR
Vibration Resistant Conductor Designs:
VR Conductor - A wind induced motion resistant conductor, VR conductor is designed
for use as a bare overhead conductor in areas subject to aeolian vibration and galloping due to
wind and ice. Use of this conductor allows it to be strung to the maximum allowable NESC
design tensions without the need for additional vibration protection.
VR conductor is composed of two identical conductors twisted together with a nine-foot
left-hand lay, giving the conductor a spiraling "figure 8" shape. This spiraled shaped disrupts the
forces created by steady cross winds by presenting a continuously changing projected conductor
diameter to the wind. By disrupting the forces created by turbulent wind flow, conductor
vibration is prevented. This unique spiral shape, together with less torsional stiffness and varying
bending stiffness also reduces or eliminates conductor galloping due to combined ice and wind
loads.
VR conductor can be made of component conductors of AAC, AAAC, ACAR, ACSR,
AAC/TW or ACSR/TW meeting the appropriate requirements. The type component or sub
conductor selected should be based on strength and thermal requirements. Constructions are
available in all conductor sizes and are suitable for both distribution and transmission
requirements.
VR conductor is typically manufactured and sold as an alternate to standard round conductor.
The total circular mil area of both component conductors equals the circular mil area of the VR
construction. Conductor constructions are normally referred to by the registered code name of
the component conductors followed by the VR designation, i.e., "Ibis/VR".
VR CONDUCTOR
ACSR/SD - Sometimes called SDC (Self Damping Conductor), ACSR/SD is a
concentric lay stranded, self damping conductor designed to control aeolian type vibration in
overhead transmission lines by internal damping. Self damping conductors consists of a central
core of one or more round steel wires surrounded by two layers of trapezoidal shaped aluminum
wires. One or more layers of round aluminum wires may be added as required.
Self damping conductor differs from conventional ACSR in that the aluminum wires in
the first two layers are trapezoidal shaped and sized so that each aluminum layer forms a
stranded tube which does not collapse onto the layer beneath when under tension, but maintains a
small annular gap between layers. The trapezoidal wire layers are separated from each other and
form the steel core by the two smaller annular gaps that permit movement between the layers.
The round aluminum wire layers are in tight contact with each other and the underlying
trapezoidal wire layer.
ACSR/SD has been very effective in reducing aeolian vibration on transmission lines.
However, most contractors charge a premium for installation because of special hardware
requirements and specialized stringing methods.
SELF DAMPING CONDUCTOR
Bundled Condctors - A bundled conductor arrangement with two or more conductors in
parallel, spaced a short distance apart is frequently used for HV and EHV transmission lines.
Many electrical reasons can be cited in favor of bundled conductors. From the stand point of
current density per unit area, smaller conductors have higher possible current densities, thus
greater metal efficiency. The use of multiple conductors per phase having the same total area as a
single conductor will operate at lower temperatures yielding lower resistances and losses for
equal loads.
Multiple conductors offer significant improvements in reactance over a single conductor
of equal area. The inductive reactance of a two conductor bundle is only about 50% of the
reactance for a single conductor having the same circular mil area as the bundled pair.
Obviously, the greater the spacing between sub conductors, the lower the reactance.
Although important, the electrical advantages of bundled conductors may not be the most
important factor influencing their use. The concerns of corona and radio noise may dictate the
use of bundled conductors since corona loss of a conductor is a function of the voltage gradient
at the conductor surface. The subjects of corona and RIV have been well investigated and will
not be further discussed here.
The number and size of conductors per phase have not been standardized. It is dependent
upon many factors. Today conductor bundles are a standard design practice for transmission
lines designed to operate at 345 kV or higher.
Any of the above discussed conductors including VR Cable, can be used as sub
conductors for bundle conductor designs. This presents the transmission design engineer with
limitless design options.
BUNDLED CONDUCTOR
Surface Finishes:
The surface of a conductor must be relatively clean and smooth to perform satisfactorily
as an electrical conductor. However, special surface treatments or finishes may be required to
reduce reflectivity or impart other desired special appearance, or in some cases aerodynamic,
characteristics to a conductor or conductor assembly. The most common surface treatment and
one normally required for conductors used for transmission and distribution lines crossing
undeveloped Federal Government park lands is one to reduce the reflectivity of aluminum
conductors. This type of surface finish is referred to as non-secular.
NON-SPECULAR CONDUCTOR - The term non-secular is used to infer that the surface of an
aluminum conductor, any type aluminum conductor, has been either mechanically or chemically
treated to produce reduced reflectivity. The conductor surface must have a smooth matte gray
finish which blends naturally and unobtrusively with the environment.
This non-secular finish is typically achieved by passing the finished conductor through a
declaring machine (a type of sandblast machine) in which the conductor surface is blasted with a
very fine mild abrasive grit producing a dull matte gray finish. The reflectivity and color of the
finished cable is specified by ANSI C7.69 Specifications.
The abrasive action of the blast media is extremely mild and in no way affects the
mechanical characteristics of the conductor. The ampacity of current carrying capability of non-
specular conductors is slightly increased because the emissivity of the conductor is increased
from approximately 0.23, for bright shiny conductors, to approximately 0.42 because of the
darker matte gray surface. An increase in current carrying capacity in the range of 5% can be
achieved, for the same temperature rise, due to this increase in surface emissivity.
Other surface finishes providing benefits such as improved aerodynamic characteristics
have been reported. The merits of such finishes must be evaluated to determine if lasting
economic benefits exist.
DISTRIBUTION CONDUCTORS
One area in the electrical power industry that has undergone extensive change is the type of
conductors available to transmit and distribute electricity. Copper was the first metal used to
transmit electricity during the development of the electrical industry in the early 1880s. Copper
conducting sizing for distribution was determined by strength requirements, with load
requirements as a secondary factor. From the standpoint of efficient electrical conductivity and
ampacity, conductors were generally larger than required. Because of the weight of the copper
conductors, span lengths were short, thus increasing the overall cost of the distribution line.
Aluminum began replacing copper as the metal of choice for transmission and distribution
conductors around 1895 in California. Since that evolution, aluminum has been used by electric
utilities for the transmission and distribution of electric power. Aluminum rank second only to
copper in volume conductivity and possesses a conductivity to weight ratio twice that of the
copper. Its strength to weight ratio is 30 percent greater than copper.
With the introduction of the aluminum conductor as a transmission and distribution conductor,
the need for a conductor with a greater strength to weight ratio was soon realized. In 1907, a new
aluminum steel composite cable, which combined light weight aluminum with the high strength
of a steel inner core, was introduced. This new steel reinforced aluminum conductor became
known as ASCR and rapid acceptance through 1939.
Soon after, an all aluminum – magnesium – silicon alloy was introduced. The new all –
aluminum alloy cable (AAAC) had comparable mechanical and electrical properties to ACSR,
but improved weight and corrosion resistance characteristics. More recently, new alloys have
been developed to provide thermal stability, increased conductivity, vibration resistance, and
other specific characteristics. There are four types of overhead conductors used in the industry
for electrical transmission and distribution. These conductors are as follows:
 AAC (all – aluminum conductor)
 AAAC (all – aluminum – alloy conductor)
 ACSR (aluminum conductor, steel reinforced)
 ACAR (aluminum conductor, aluminum – alloy reinforced)
Transmission and distribution systems usually contain a combination of these conductors in
various configurations, all uniquely designed into total system whose primary purpose is to
deliver electrical power to the consumers.
AAC CABLE
AAAC CABLE
ACSR CABLE
ACAR CABLE
CONCLUSION:
The selection of the optimum conductor type and size for a given line consists of finding that
conductor which results in the lowest present net worth cost spread over the life of the line. The
transmission line design engineer is confronted with choosing a conductor type from among this
bewildering assortment. This choice must be based on basic conductor parameters.
It is clear that all the major cost components of a transmission line depend upon conductor
physical, mechanical and electrical parameters. A list of these basic parameters are:
 conductor diameter
 weight per unit length
 conductivity of material(s)
 crossectional area(s)
 modulus of elasticity
 rated breaking strength
 coefficient(s) of thermal expansion
 cost of material(s)
 maximum unloaded design tension
 resistance to vibration and/or galloping
 surface shape/drag coefficient
 fatigue resistance
These basic parameters are not necessarily independent of one another. However, certain
parameters can be varied independently over a range of design considerations.
It is the hope of this writer that a better understanding of available conductor types and materials
will provide a better base for future conductor selections.

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Conductors

  • 1. INTRODUCTION Conductor: The coil from a electric heater gets hot and conducts electricity well. A conductor is something which allows electricity to flow through. • An example of a conductor is: – Scissors – Paper clip – Aluminum foil – Iron – Steel – Copper
  • 2. In all good conductors electric current flows through them without resistance. Example: Electricity flows through the coil in the power line coils without resistance and easily When it comes to the flow of electric current, all materials fall into three categories: • insulators • conductors • resistors
  • 3. Insulator • Any material that does not allow electric current to pass through it Insulators like plastic and rubber are used as a covering for electric wires. This makes electric wires safer to handle because the insulator protects you from the current.
  • 5. Resistor A material or a device that allows some current to pass but converts some of the current to another form of energy.
  • 6. An electrical conductor is a substance in which electrical charge carriers, usually electrons, move easily from atom to atom with the application of voltage. Conductivity, in general, is the capacity to transmit something, such as electricity or heat. Pure elemental silver is the best electrical conductor encountered in everyday life. Copper, steel, gold, aluminum, and brass are also good conductors. In electrical and electronic systems, all conductors comprise solid metals molded into wires or etched onto circuit boards. Some liquids are good electrical conductors. Mercury is an excellent example. A saturated salt-water solution acts as a fair conductor. Gases are normally poor conductors because the atoms are too far apart to allow a free exchange of electrons. However, if a sample of gas contains a significant number of ions, it can act as a fair conductor. A substance that does not conduct electricity is called an insulator or dielectric material. Common examples include most gases, porcelain, glass, plastic, and distilled water. A material that conducts fairly well, but not very well, is known as a resistor. The most common example is a combination of carbon and clay, mixed together in a specific ratio to produce a constant and predictable opposition to electric current. Substances called semiconductors act as good conductors under some conditions and poor conductors under other conditions. Silicon, germanium, and various metal oxides are examples of semiconductor materials. In a semico
  • 7. CONDUCTORS MATERIALS Conduction materials include metals, electrolytes, superconductors, semiconductors, plasmas and some nonmetallic conductors such as graphite and Conductive polymers. Copper has a high conductivity. Annealed copper is the international standard to which all other electrical conductors are compared. The main grade of copper used for electrical applications, such as building wire, motor windings, cables and busbars, is electrolytic-tough pitch (ETP) copper (CW004A or ASTM designation C100140). This copper has an electrical conductivity of at least 101% IACS (International Annealed Copper Standard). If high conductivity copper must be welded or brazed or used in a reducing atmosphere, then oxygen-free high conductivity copper (CW008A or ASTM designation C10100) may be used.[2] Because of its ease of connection by soldering or clamping, copper is still the most common choice for most light-gauge wires. Silver is more 'conductive' than copper, but due to cost it is not practical in most cases. However, it is used in specialized equipment, such as satellites, and as a thin plating to mitigate skin effect losses at high frequencies. Aluminum wire, which has 61% of the conductivity of copper, has been used in building wiring for its lower cost. By weight, aluminum has higher conductivity than copper, but it has properties that cause problems when used for building wiring. It can form a resistive oxide within connections that makes wiring terminals heat. Aluminum can "creep", slowly deforming under load, eventually causing device connections to loosen, and also has a different coefficient of thermal expansion compared to materials used for connections. This accelerates the loosening of connections. These effects can be avoided by using wiring devices approved for use with aluminum. Aluminum wires used for low voltage distribution, such as buried cables and service drops, require use of compatible connectors and installation methods to prevent heating at joints. Aluminum is also the most common metal used in high-voltage transmission lines, in combination with steel as structural reinforcement.
  • 8. Anodized aluminum surfaces are not conductive. This affects the design of electrical enclosures that require the enclosure to be electrically connected. Organic compounds such as octane, which has 8 carbon atoms and 18 hydrogen atoms, cannot conduct electricity. Oils are hydrocarbons, since carbon has the property of tetracovalency and forms covalent bonds with other elements such as hydrogen, since it does not lose or gain electrons, thus does not form ions. Covalent bonds are simply the sharing of electrons. Hence, there is no separation of ions when electricity is passed through it. So the liquid (oil or any organic compound) cannot conduct electricity. While pure water is not an electrical conductor, even a small portion of impurities, such as salt, can rapidly transform it into a conductor. TYPES OF CONDUCTORS: There is no unique process by which all transmission and/or distribution lines are designed. It is clear, however, that all major cost components of line design depend upon the conductor electrical and mechanical parameters. There are four major types of overhead conductors used for electrical transmission and distribution.  AAC - All Aluminum Conductor  AAAC - All Aluminum Alloy Conductor  ACSR - Aluminum Conductor Steel Reinforced  ACAR - Aluminum Conductor Aluminum-Alloy Reinforced The various combinations and modifications of these conductor types provide a wide variety of possible conductor designs. AAC - All Aluminum Conductor, sometimes referred to as ASC, Aluminum Stranded Conductor, is made up of one or more strands of 1350 Alloy Aluminum in the hard drawn H19 temper. 1350 Aluminum Alloy, previously known as EC grade or electrical conductor grade
  • 9. aluminum, has a minimum conductivity of 61.2% IACS. Because of its relatively poor strength- to-weight ratio, AAC has had limited use in transmission lines and rural distribution because of the long spans utilized. However, AAC has seen extensive use in urban areas where spans are usually short but high conductivity is required. The excellent corrosion resistance of aluminum has made AAC a conductor of choice in coastal areas. ACSR - Aluminum Conductor Steel Reinforced, a standard of the electrical utility industry since the early 1900's, consists of a solid or stranded steel core surrounded by one or more layers of strands of 1350 aluminum. Historically, the amount of steel used to obtain higher strength soon increased to a substantial portion of the cross-section of the ACSR, but more recently, as conductors have become larger, the trend has been to less steel content. To meet varying requirements, ACSR is available in a wide range of steel content - from 7% by weight for the 36/1 stranding to 40% for the 30/7 stranding. Early designs of ACSR such as 6/1, 30/7, 30/19, 54/19 and 54/7 strandings featured high steel content, 26% to 40%, with emphasis on strength perhaps due to fears of vibration fatigue problems. Today, for larger-than-AWG sizes, the most used strandings are 18/1, 45/7, 72/7, and 84/19, comprising a range of steel content from 11% to 18%. For the moderately higher strength 54/19, 54/7, and 26/7 strandings, the steel content is 26%, 26% and 31%, respectively. The high-strength ACSR 8/1, 12/7 and 16/19 strandings, are used mostly for overhead ground wires, extra long spans, river crossings, etc. The inner-core wires of ACSR may be of zinc coated (galvanized) steel, available in standard weight Class A coating or heavier coatings of Class B or Class C. Class B coatings are about twice the thickness of Class A, and Class C coatings about three times as thick as Class A. The inner cores may also be of aluminum coated (aluminized) steel or aluminum clad steel. The latter produces a conductor designated as ACSR/AW in which the aluminum cladding comprises 25% of the area of the wire, with a minimum coating thickness of 10% of the overall radius. The reinforcing wires may be in a central core or distributed throughout the cable. Galvanized or aluminized coats are thin, and are applied to reduce corrosion of the steel wires. The conductivity of these thin coated core wires is about 8% IACS. The apparent conductivity of ACSR/AW reinforcement wire is 20.3% IACS.
  • 10. ACSR STRANDINGS 6201 "AAAC" - A high strength Aluminum-Magnesium-Silicon Alloy Cable was developed to replace the high strength 6/1 ACSR conductors. Originally called AAAC, this alloy conductor offers excellent electrical characteristics with a conductivity of 52.5% IACS, excellent sag-tension characteristics and superior corrosion resistance to that of ACSR. The temper of 6201 is normally T81. 6201 aluminum alloy conductors are typically sold as O.D. equivalents for 6/1 and 26/7 ACSR constructions. The O.D. equivalent 6201 conductors have approximately the same ampacity and strength as their ACSR counterparts with a much improved strength-to-weight ratio. 6201 conductors also exhibit substantially better electrical loss characteristics than their equivalent single layer ACSR constructions. However, the thermal coefficient of expansion is greater than that of ACSR. As with AAC conductors, the maximum short circuit temperature of 6201 must be kept below 340°C to prevent dangerous conductor annealing. As compared to ACSR, AAAC's ligher weight, comparable strength and current carrying capacity, lower electrical losses and superior corrosion resistance have given this conductor wide acceptance as a distribution conductor. It has found limited use, however, as a transmission conductor. ACAR - (Aluminum Conductor-Aluminum Alloy Reinforced) - ACAR combines 1350 and 6201 aluminum alloy strands to provide a transmission conductor with an excellent balance of electrical and mechanical properties. This conductor consists of one or more layers of 1350-H19 aluminum strands helically wrapped over one or more 6201-T81 aluminum alloy wires. The core may consist of one or more 6201 strands. The primary advantage of the ACAR conductor lies in the fact that all strands are interchangeable between EC and 6201, thereby permitting the design of a conductor with an optimum balance between mechanical and electrical characteristics. In effect, ACAR is a composite aluminum-aluminum alloy conductor which is designed for each application to optimize properties. Inverse ACAR conductors are also available with the harder 6201 aluminum alloy wires being on the outer surface of the conductor and the 1350 aluminum making up the heart of the conductor.
  • 11. Typical Stranding For Concentric-Lay-Stranded ACAR Conductors AACSR - (6201 Aluminum Alloy Conductor Steel Reinforced) - Is an ACSR with the 1350 aluminum wires replaced by 6201-T81 aluminum alloy wires. The high tensile strength of the 6201-T81 wires combined with the high strength of steel provides an exceptionally high strength conductor with good conductivity. AACSR conductors have approximately 40% to 60% more strength than comparable standard ACSR conductors of equivalent stranding, with only an 8- 10% decrease in conductivity. AACSR is available with all core types specified for use with standard ACSR. SSAC - (Steel Supported Aluminum Cable) - SSAC conductor was designed for use as a replacement conductor in upgrading existing transmission and distribution lines with minimum capital outlay. The premise of design is higher conductor operating temperature without detrimental annealing of the aluminum in standard ACSR causing a loss of strength in the aluminum. SSAC conductor is an aluminum-steel composite conductor resembling standard ACSR in appearance, stranding and overall diameter. This is the extent of their similarities however. SSAC uses 1350-0 (fully annealed) aluminum strands with 63.0% conductivity rather than the traditional 1350-H19 hard drawn aluminum used in standard ACSR which possesses 61.2% IACS conductivity. The steel core may be made of conventional or extra high strength steel core wire. Compared to an equal size ACSR, SSAC has a lower resistance, lower breaking strength, lower creep elongation and lower elastic modulus. SSAC can be operated at temperatures as high as 250°C without loss of strength and can be strung at higher unloaded percentage tensions because of its good self damping characteristics. SSAC has seen limited use in the United States. Even though SSAC has better conductivity, a higher operating temperature and improved damping characteristics when compared to conventional ACSR, it has a lower breaking strength, typically yielding greater initial and final sags. It is, however, a good conductor to consider for line upgrades if the calculated present worth of electrical losses shows a savings over line conversion cost. Expanded ACSR - This conductor is designed to be used where large diameter single conductors are required to reduce the electrical stress gradient at the surface of the conductor to provide corona-free operation. Expanded ACSR is used when a single conductor rather than a
  • 12. conductor bundle is used at EHV voltage levels. Expanded ACSR is specially fabricated to have a larger outside diameter than could be achieved using the circular mil area of aluminum required. Expansion is achieved by the use of oversized wires widely spaced in successive wire layers near the core. Expansion has also been achieved by the use of extruded metal shapes and various rope, paper or jute fillers. Expanded conductors can offer improved sag characteristics as well as efficient design. Because of the precise fabrication techniques required to manufacture expanded conductors and a history of installation problems, these conductors have not been widely used. Smooth Body Conductors: Some cables are designed to produce a smooth outer surface and reduce overall diameter. This smaller diameter reduces the ice and wind loading encountered during severe weather, thereby reducing the pole/tower loading or allowing longer design spans. Smooth body conductors are of two types - compact conductors or trapezoidal shaped wire compact conductors, i.e., TW conductors. Compact Conductors - Compact overhead conductors are typiclly available in both AAC and ACSR with diameter reductions ranging from 8% to 11%. AAC conductors are available in a size range of #8 AWG through 1000 kcmil with standard stranding as listed in ASTM. Compact ACSR conductors are available only in sizes #6 AWG through 336.4 kcmil in constructions with a single steel core wire. Compact conductors are manufactured by passing the stranded cable through powerful compacting rolls or a compacting die. The strands are deformed, to the degree they loose their circularity, partially filling the interstrand voids and the outer surface of the conductor becomes a relatively smooth cylinder. The resulting reduction in overall diameter not only reduces the ice and wind loading characteristics of the conductor but also reduces the stress gradient at the conductor surface. 150% / 200% ACSR - The terms 150% and 200% ACSR refer to a family of single layer (6/1) constructions of ACSR that have 150% and 200% of the strength of the equivalent construction standard ACSR while exhibiting approximately the same overall diameter. The 150% and 200%
  • 13. smooth body ACSR was developed to provide a conductor with a substantial increase in ultimate strength as compared to standard 6/1 ACSR constructions. This is accomplished by using a larger steel core wire and drastically flattening the aluminum strands to create a smooth cylindrical conductor surface. 150% and 200% smooth body ACSR is fabricated by passing the composite stranded cable through a die or rolls so designed to flatten the aluminum strands and fill the interstices which exist in conventional stranded ACSR. This brings about a reduction in overall cable diameter which means a lower ice and wind load and greater strength to loaded weight ratio. These conductors were primarily designed for use on rural distribution lines. The reduced diameter and extra high strength provide substantial design and operational advantages for the longer spans of a rural distribution line serving sparcely populated areas subject to severe cold weather conditions. Trapezoidal Shaped Wire Conductors - Shaped wire compact conductors made from trapezoidal (TW) shaped wires is a relatively new conductor design. These conductors can be provided in AAC, AAAC and ACSR constructions and are designated as types AAC/TW, AAAC/TW and ACSR/TW. Conventional conductor designs have traditionally used round wires. The use of technology to design and produce trapezoidal wires (TW) provides conductor designers with an alternative to conventional round strand conductor designs. The use of trapezoidal wire designs yields compact conductors with less void area and a reduced outside diameter. With conventional ACSR strandings, the number of aluminum and steel strands uniquely define the ratio of steel area to aluminum area. For example, all 26/7 ACSR constructions have the same ratio of steel area to aluminum area of about 16%. However, with TW strands the number of aluminum and steel strands do not necessarily define a unique steel to aluminum ratio. Therefore the designation of "type" has replaced the stranding designation to more accurately identify TW conductors. For example a 795 kcmil-26/7 ACSR "Drake" has a TW counterpart designated 795 kcmil Type 16, ACSR/TW. The aluminum area and steel area of both conductors
  • 14. are identical. The use of TW shaped aluminum strands will cause the ACSR/TW to have a smaller diameter. The following table relates ACSR/TW Type Number with standard conventional ACSR stranding. Comparison of ACSR/TW with equivalent stranding of ACSR ACSR/TW TYPE CONVENTIONAL ACSR Number* Stranding* 5 42/7 7 45/7 8 84/19 10 22/7 13 54/7 13 54/19 15 26/7 Comparison of ACSR/TW with equivalent stranding of ACSR ACSR/TW type conventional ACSR Number* Stranding 5 42/7 7 45/7 8 84/19 10 22/7 13 54/7 13 54/19 15 26/7 An alternate design concept is to specify ACSR/TW conductors with equivalent overall diameters to conventional ACSR constructions. In this case, the diameter is matched to that of the standard ACSR while maintaining the same ratio of steel to aluminum by area. Since the aluminum area is increased, the steel area must be increased to maintain the proper area ratio.
  • 15. If a reduced diameter TW construction is selected, the diameter is reduced by approximately 10% thereby reducing the design ice and wind loading on the conductor. If an equal diameter TW construction is selected, the aluminum area is increased by approximately 20% - 25% providing a decrease in AC resistance of 15% - 20% and increasing the current carrying capacity 8% to 10%. The use of trapezoidal wires provides a more compact conductor design with mechanical properties at least equal to that of conventional ACSR. Since ACSR/TW designs have the same steel-to-aluminum ratios as their equivalent ACSR constructions, stress-strain and creep data developed for conventional strandings of ACSR can be used to predict sag and tension design data for ACSR/TW conductor constructions. TW conductor installation requires no special tools, equipment or training.
  • 16. ACSR TRAPEZOIDAL SHAPED WIRE CONDUCTOR Vibration Resistant Conductor Designs: VR Conductor - A wind induced motion resistant conductor, VR conductor is designed for use as a bare overhead conductor in areas subject to aeolian vibration and galloping due to wind and ice. Use of this conductor allows it to be strung to the maximum allowable NESC design tensions without the need for additional vibration protection. VR conductor is composed of two identical conductors twisted together with a nine-foot left-hand lay, giving the conductor a spiraling "figure 8" shape. This spiraled shaped disrupts the forces created by steady cross winds by presenting a continuously changing projected conductor diameter to the wind. By disrupting the forces created by turbulent wind flow, conductor vibration is prevented. This unique spiral shape, together with less torsional stiffness and varying bending stiffness also reduces or eliminates conductor galloping due to combined ice and wind loads. VR conductor can be made of component conductors of AAC, AAAC, ACAR, ACSR, AAC/TW or ACSR/TW meeting the appropriate requirements. The type component or sub conductor selected should be based on strength and thermal requirements. Constructions are available in all conductor sizes and are suitable for both distribution and transmission requirements. VR conductor is typically manufactured and sold as an alternate to standard round conductor. The total circular mil area of both component conductors equals the circular mil area of the VR construction. Conductor constructions are normally referred to by the registered code name of the component conductors followed by the VR designation, i.e., "Ibis/VR".
  • 17. VR CONDUCTOR ACSR/SD - Sometimes called SDC (Self Damping Conductor), ACSR/SD is a concentric lay stranded, self damping conductor designed to control aeolian type vibration in overhead transmission lines by internal damping. Self damping conductors consists of a central core of one or more round steel wires surrounded by two layers of trapezoidal shaped aluminum wires. One or more layers of round aluminum wires may be added as required. Self damping conductor differs from conventional ACSR in that the aluminum wires in the first two layers are trapezoidal shaped and sized so that each aluminum layer forms a stranded tube which does not collapse onto the layer beneath when under tension, but maintains a small annular gap between layers. The trapezoidal wire layers are separated from each other and form the steel core by the two smaller annular gaps that permit movement between the layers. The round aluminum wire layers are in tight contact with each other and the underlying trapezoidal wire layer. ACSR/SD has been very effective in reducing aeolian vibration on transmission lines. However, most contractors charge a premium for installation because of special hardware requirements and specialized stringing methods. SELF DAMPING CONDUCTOR Bundled Condctors - A bundled conductor arrangement with two or more conductors in parallel, spaced a short distance apart is frequently used for HV and EHV transmission lines. Many electrical reasons can be cited in favor of bundled conductors. From the stand point of current density per unit area, smaller conductors have higher possible current densities, thus greater metal efficiency. The use of multiple conductors per phase having the same total area as a single conductor will operate at lower temperatures yielding lower resistances and losses for equal loads. Multiple conductors offer significant improvements in reactance over a single conductor of equal area. The inductive reactance of a two conductor bundle is only about 50% of the reactance for a single conductor having the same circular mil area as the bundled pair. Obviously, the greater the spacing between sub conductors, the lower the reactance.
  • 18. Although important, the electrical advantages of bundled conductors may not be the most important factor influencing their use. The concerns of corona and radio noise may dictate the use of bundled conductors since corona loss of a conductor is a function of the voltage gradient at the conductor surface. The subjects of corona and RIV have been well investigated and will not be further discussed here. The number and size of conductors per phase have not been standardized. It is dependent upon many factors. Today conductor bundles are a standard design practice for transmission lines designed to operate at 345 kV or higher. Any of the above discussed conductors including VR Cable, can be used as sub conductors for bundle conductor designs. This presents the transmission design engineer with limitless design options. BUNDLED CONDUCTOR Surface Finishes: The surface of a conductor must be relatively clean and smooth to perform satisfactorily as an electrical conductor. However, special surface treatments or finishes may be required to reduce reflectivity or impart other desired special appearance, or in some cases aerodynamic, characteristics to a conductor or conductor assembly. The most common surface treatment and one normally required for conductors used for transmission and distribution lines crossing undeveloped Federal Government park lands is one to reduce the reflectivity of aluminum conductors. This type of surface finish is referred to as non-secular. NON-SPECULAR CONDUCTOR - The term non-secular is used to infer that the surface of an aluminum conductor, any type aluminum conductor, has been either mechanically or chemically treated to produce reduced reflectivity. The conductor surface must have a smooth matte gray finish which blends naturally and unobtrusively with the environment. This non-secular finish is typically achieved by passing the finished conductor through a declaring machine (a type of sandblast machine) in which the conductor surface is blasted with a
  • 19. very fine mild abrasive grit producing a dull matte gray finish. The reflectivity and color of the finished cable is specified by ANSI C7.69 Specifications. The abrasive action of the blast media is extremely mild and in no way affects the mechanical characteristics of the conductor. The ampacity of current carrying capability of non- specular conductors is slightly increased because the emissivity of the conductor is increased from approximately 0.23, for bright shiny conductors, to approximately 0.42 because of the darker matte gray surface. An increase in current carrying capacity in the range of 5% can be achieved, for the same temperature rise, due to this increase in surface emissivity. Other surface finishes providing benefits such as improved aerodynamic characteristics have been reported. The merits of such finishes must be evaluated to determine if lasting economic benefits exist.
  • 20. DISTRIBUTION CONDUCTORS One area in the electrical power industry that has undergone extensive change is the type of conductors available to transmit and distribute electricity. Copper was the first metal used to transmit electricity during the development of the electrical industry in the early 1880s. Copper conducting sizing for distribution was determined by strength requirements, with load requirements as a secondary factor. From the standpoint of efficient electrical conductivity and ampacity, conductors were generally larger than required. Because of the weight of the copper conductors, span lengths were short, thus increasing the overall cost of the distribution line. Aluminum began replacing copper as the metal of choice for transmission and distribution conductors around 1895 in California. Since that evolution, aluminum has been used by electric utilities for the transmission and distribution of electric power. Aluminum rank second only to copper in volume conductivity and possesses a conductivity to weight ratio twice that of the copper. Its strength to weight ratio is 30 percent greater than copper. With the introduction of the aluminum conductor as a transmission and distribution conductor, the need for a conductor with a greater strength to weight ratio was soon realized. In 1907, a new aluminum steel composite cable, which combined light weight aluminum with the high strength of a steel inner core, was introduced. This new steel reinforced aluminum conductor became known as ASCR and rapid acceptance through 1939. Soon after, an all aluminum – magnesium – silicon alloy was introduced. The new all – aluminum alloy cable (AAAC) had comparable mechanical and electrical properties to ACSR, but improved weight and corrosion resistance characteristics. More recently, new alloys have been developed to provide thermal stability, increased conductivity, vibration resistance, and other specific characteristics. There are four types of overhead conductors used in the industry for electrical transmission and distribution. These conductors are as follows:  AAC (all – aluminum conductor)  AAAC (all – aluminum – alloy conductor)  ACSR (aluminum conductor, steel reinforced)  ACAR (aluminum conductor, aluminum – alloy reinforced)
  • 21. Transmission and distribution systems usually contain a combination of these conductors in various configurations, all uniquely designed into total system whose primary purpose is to deliver electrical power to the consumers. AAC CABLE AAAC CABLE
  • 23. CONCLUSION: The selection of the optimum conductor type and size for a given line consists of finding that conductor which results in the lowest present net worth cost spread over the life of the line. The transmission line design engineer is confronted with choosing a conductor type from among this bewildering assortment. This choice must be based on basic conductor parameters. It is clear that all the major cost components of a transmission line depend upon conductor physical, mechanical and electrical parameters. A list of these basic parameters are:  conductor diameter  weight per unit length  conductivity of material(s)  crossectional area(s)  modulus of elasticity  rated breaking strength  coefficient(s) of thermal expansion  cost of material(s)  maximum unloaded design tension  resistance to vibration and/or galloping  surface shape/drag coefficient  fatigue resistance These basic parameters are not necessarily independent of one another. However, certain parameters can be varied independently over a range of design considerations. It is the hope of this writer that a better understanding of available conductor types and materials will provide a better base for future conductor selections.