ES 01-0500 Bare Aluminium Conductors for Overhead Lines[1]

Document Number: ES 01-0500

Version: 04

Date: 07/12/2007

1 of 13

EQUIPMENT SPECIFICATION

ES 01-0500

BARE ALUMINIUM CONDUCTORS FOR OVERHEAD LINES

Network(s): EPN, SPN

Summary: This equipment specification details the requirements for all aluminium-based stranded conductors for use in overhead line construction.

Originator: Jon Kenrick Date: 07/12/2007

Approved By: Paul Elliott Approved Date: 12/12/2007

Review Date: 12/12/2010

This document forms part of the Company’s Integrated Business System and its requirements are mandatory throughout EDF Energy Networks Branch. Departure from these requirements may only be taken with the written approval of Asset Management. If you have any queries about this document please contact the originator of the current issue.

Document History (The document history notes below are intended as a guide only and may not cover all of the changes. If you wish to make use of this document it should be read in full.)

Version Date Details Originator

01 01/12/1993 Original Previous Originator

02 07/05/2002 Specifications updated Martin Payne

03 24/10/2003 Incorporating EDF Energy branch-wide Jon Kenrick

04 07/12/2007 Revised layout conforming to latest EDF Energy template; greasing specification added; type test sheet added

Jon Kenrick


Version: 04

Bare Aluminium Conductors for Overhead Lines

Date: 07/12/2007

Contents

1 Scope ..........................................................................................................................4 2 References..................................................................................................................4 3 Definitions...................................................................................................................4 4 General Requirements...............................................................................................5 4.1 Functions of the Equipment ........................................................................................ 5 4.2 System Environment ................................................................................................... 5 4.3 Environment ................................................................................................................ 5 4.4 Disposal Requirements ............................................................................................... 5 4.4.1 Disposal of Packaging & Installation Waste................................................................ 5 4.4.2 Disposal of Consumables (if applicable) ..................................................................... 5 4.4.3 Disposal of Equipment at End of Life .......................................................................... 5 5 Technical Requirements............................................................................................6 5.1 Stranded Conductor .................................................................................................... 6 5.1.1 Material ....................................................................................................................... 6 5.1.2 Size ............................................................................................................................. 6 5.1.3 Surface condition ........................................................................................................ 6 5.1.4 Diameter...................................................................................................................... 6 5.1.5 Stranding..................................................................................................................... 6 5.1.6 Joints........................................................................................................................... 6 5.1.7 Mass per unit length.................................................................................................... 6 5.1.8 Number and type of wires ........................................................................................... 6 5.1.9 Stress-strain curve ...................................................................................................... 6 5.1.10 Tensile breaking strength............................................................................................ 6 5.1.11 Stringing ...................................................................................................................... 7 5.1.12 Resistivity (nominal d.c. resistance)............................................................................ 7 5.2 Grease ........................................................................................................................ 7 5.2.1 General Requirements ................................................................................................ 7 5.2.2 Greasing Category ...................................................................................................... 7 6 Testing ........................................................................................................................7 6.1 Sample (Routine) Tests .............................................................................................. 7 6.2 Type Tests .................................................................................................................. 7 6.3 Special Tests............................................................................................................... 7 7 Packaging & Marking.................................................................................................7 7.1 Packaging ................................................................................................................... 7 7.2 Marking and tare ......................................................................................................... 8

2 of 13


Version: 04


Date: 07/12/2007

7.3 Random lengths .......................................................................................................... 8 7.4 Accuracy of lengths..................................................................................................... 8 7.5 Drum barrel dimensions .............................................................................................. 8 8 Documentation ...........................................................................................................8 8.1 Environmental Management, Quality Assurance and health and Safety

Management ............................................................................................................... 8 8.2 Information Required with the Offer ............................................................................ 8 8.3 Information Required before Delivery ......................................................................... 9 8.3.1 Installation Manual ...................................................................................................... 9 8.3.2 Operation and Maintenance Manual ........................................................................... 9 8.3.3 Contract Drawings....................................................................................................... 9 8.3.4 Health and Safety Documentation .............................................................................. 9 9 Delivery .....................................................................................................................10 10 Tender Assessment .................................................................................................10 Appendix A - Schedule of Requirements ..........................................................................11 Appendix B - Information to be provided by Supplier......................................................12

3 of 13


Version: 04


Date: 07/12/2007

1 Scope This equipment specification details the requirements for all aluminium-based stranded conductors for use in overhead line construction.

2 References The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.

Standard Number Standard Description

BS EN ISO 9001 Quality Management Systems. Requirements

BS EN ISO 14001 Environmental Management Systems - requirements with guidance for use

OHSAS 18001 Occupational Health& Safety Management System

BS EN 50182 Conductors for overhead lines – Round wire concentric lay stranded conductors

ENA ER L38/1 Recommendation for the Protective Greasing of PVC-Covered Copper and Bare and PVC-Covered Aluminium Based Overhead Line Conductors

3 Definitions ‘Supplier’ refers to a manufacturer or other organisation supplying equipment for use on EDF Energy’s Networks.

‘EDF Energy’ refers to EDF Energy Networks Ltd., the Purchaser

‘East of England Network’ refers to the distribution network for which EDF Energy Networks (EPN) plc is the licence holder.

‘London Network’ refers to the distribution network for which EDF Energy Networks (LPN) plc is the licence holder.

Southeast Network refers to the distribution network for which EDF Energy Networks (SPN) plc is the licence holder.

4 of 13


Version: 04


Date: 07/12/2007

4 General Requirements The detailed requirements of the conductors are listed in Appendix A.

4.1 Functions of the Equipment

Bare aluminium stranded conductors manufactured to this specification are for use as electrical current carrying purposes only, tensioned at height between suitable supports.

4.2 System Environment

Conductors manufactured to this specification are for use on the EDF Energy Networks overhead line electrical system, at operating voltages from LV (240V) to 132kV inclusive.

4.3 Environment

Conductors manufactured to this specification shall be subjected to the following environmental criteria:

• Ambient air temperature range of -20°C to +40°C • Solar radiation up to a level of 1200 W/m² • Wind and radial ice loadings of 380 N/m² and 9.5mm respectively

4.4 Disposal Requirements

4.4.1 Disposal of Packaging & Installation Waste

The Supplier shall ensure that any waste produced as the result of the fitting’s packaging and installation is fully recyclable.

4.4.2 Disposal of Consumables (if applicable)

Any consumables required during installation shall be fully recyclable.

4.4.3 Disposal of Equipment at End of Life

The Supplier shall ensure that all materials used in the manufacture of the fittings are recyclable in some form.

5 of 13


Version: 04


Date: 07/12/2007

5 Technical Requirements

5.1 Stranded Conductor

5.1.1 Material

Compliant with 5.1 of BS EN 50182.

5.1.2 Size

Compliant with 5.2 of BS EN 50182. The sizes required by EDF Energy Networks are covered in Appendix A of this specification.

5.1.3 Surface condition

Generally compliant with 5.3 of BS EN 50182. Experience will be the governing factor when it is required to determine whether any marking or damage to the conductor is bad enough to reject it.

5.1.4 Diameter

Compliant with 5.4 of BS EN 50182. The diameters stated in Annex F of BS EN 50182 shall be taken as the nominal value.

5.1.5 Stranding

Compliant with 5.5 of BS EN 50182. In the case of 5.5.2 of BS EN 50182, there may be some exceptional circumstances where a left-hand external layer may be acceptable. In any such case, the Supplier shall inform the Purchaser prior to shipment to ensure that this will be acceptable in that instance.

5.1.6 Joints


5.1.7 Mass per unit length


5.1.8 Number and type of wires

Compliant with that stated in the relevant tables of Annex F of BS EN 50182 (see Appendix A of this specification).

5.1.9 Stress-strain curve

This technical aspect is not required at this time.

5.1.10 Tensile breaking strength


6 of 13


Version: 04


Date: 07/12/2007

5.1.11 Stringing

This technical aspect is not required at this time.

5.1.12 Resistivity (nominal d.c. resistance)


5.2 Grease

5.2.1 General Requirements


5.2.2 Greasing Category

Generally, the specification for greasing shall comply with Annex B of BS EN 50182. However, the greasing category to be used in this specification shall equate to Category 3, as defined in Figure 1 (‘Conductor Grease Loading’) of ENA ER L38/1. The nearest equivalent in Annex B of BS EN 50182 is Case 2 (Figure B.1(b))

6 Testing

6.1 Sample (Routine) Tests

Routine tests to be carried out conductors manufactured to this specification shall conform to the ‘Sample test’ column of Table 5 of BS EN 50182.

6.2 Type Tests

Type tests to be carried out conductors manufactured to this specification shall conform to the ‘Type test’ column of Table 5 of BS EN 50182. Regarding the three ‘optional’ tests in the conductor section, only the tensile breaking strength shall be carried out.

6.3 Special Tests

No special tests are specified at this time.

7 Packaging & Marking

7.1 Packaging

Generally compliant with 7.1 of BS EN 50182. Compliant with a common Environmental Policy, all packaging shall be fully recyclable, or be returnable to the supplier. In the first instance the Purchaser shall make all reasonable effort to have the drums returned to the supplier for re-use.

For protection of the outer layer of the conductor length, a flexible fibre board with a plastic covering shall be used. Batons are not permitted to be nailed across the flanges of the drum.

7 of 13


Version: 04


Date: 07/12/2007

7.2 Marking and tare


7.3 Random lengths


7.4 Accuracy of lengths


7.5 Drum barrel dimensions

As with 7.5 of BS EN 50182, the barrel dimension shall be a minimum of thirty times the conductor diameter.

8 Documentation

8.1 Environmental Management, Quality Assurance and health and Safety Management

The Supplier shall have quality assurance arrangements which conform to BS EN ISO 9000: 2000, “Quality Management Systems. Requirements”

The Supplier shall have environmental management arrangements which conform to BS EN ISO 14001: 1996, “Environmental management systems - requirements with guidance for use”.

The Supplier shall show evidence that they are working towards an approved Health and Safety Management System such as OHSAS 18001.

8.2 Information Required with the Offer

The following information is required with the Offer:

• General arrangement drawings of the conductors including the number of strands, lay direction, nominal dimensions, electrical properties, mechanical properties, physical properties – which shall include the type, method and weight of grease used.

• Nominal length of conductor per drum, as well as maximum possible lengths should the stranding machine capacity be available

• Details of any significant considerations and procedures that may have an impact on health and safety matters.

• The Supplier’s Environment Policy.

• Details of the appropriate training necessary to enable the Company’s staff to safely install, operate and maintain the conductors.

8 of 13


Version: 04


Date: 07/12/2007

8.3 Information Required before Delivery

8.3.1 Installation Manual

An installation guide shall be provided for the conductors to be supplied. Further additional copies of the guide(s) as may be reasonably required by the Company, shall be supplied on request. An electronic version of the manual, in pdf format, shall also be supplied.

8.3.2 Operation and Maintenance Manual

An operations and maintenance guide shall be provided for each type of conductor to be supplied. The document shall provide the information necessary to allow safe operation and maintenance. In particular the guide shall list recommended methods of safely working at heights (where appropriate) and all normal activities associated with the conductors. Further additional copies of the guides, as may be reasonably required by the Company, shall be supplied on request. An electronic version of the manual, in pdf format, shall also be supplied.

8.3.3 Contract Drawings

A complete set of contract drawings shall be supplied. These shall include a physical drawing of the cross-section of the conductor showing the number of strands, lay direction, nominal dimensions, electrical properties, mechanical properties, physical properties – which shall include the type, method and weight of grease used.

The drawings shall be provided electronically in pdf format.

8.3.4 Health and Safety Documentation

The Supplier is required to provide Health and Safety documentation by selecting the appropriate sections from the list below, relevant to the Offer.

8.3.4.1 Disposal of Consumables

The document shall indicate how consumables associated with the equipment will be disposed of.

8.3.4.2 Hazardous Materials

A detailed list of hazardous materials associated with the equipment. The document shall contain all details of any necessary precautions for the safe use, maintenance and removal of the materials in the future.

8.3.4.3 Dismantling and Disposal

A schedule of dismantling procedures. The document shall list each significant piece of apparatus and detail how the item should be safely dismantled and disposed of at the end of its life.

9 of 13


Version: 04


Date: 07/12/2007

9 Delivery Conductors shall be delivered complete and ready for service except as set out in this specification and shall be suitably and adequately protected and supported during transit and storage.

10 Tender Assessment Technical information to be supplied by the Supplier is detailed in Appendix B.

10 of 13


Version: 04

Bare Aluminium Conductors for Overhead Lines Date: 07/12/2007

Appendix A - Schedule of Requirements

Item No. EDF Energy Networks Description Old Conductor Code Description

Table Ref. in BS EN 50182

Conductor Code / Designation

1 Conductor HDAl Bare 50mm² ANT F.39 53-AL1

2 Conductor HDAl Bare 100mm² WASP F.39 106-AL1

3 Conductor AAAC Bare 50mm² HAZEL F.40 60-AL3

4 Conductor AAAC Bare 100mm² OAK F.40 119-AL3

5 Conductor AAAC Bare 150mm² ASH F.40 181-AL3

6 Conductor AAAC Bare 200mm² POPLAR F.40 239-AL3

7 Conductor AAAC Bare 300mm² UPAS F.40 362-AL3

8 Conductor ACSR Bare 50mm² RABBIT F.42 53-AL1/9-ST1A

9 Conductor ACSR Bare 50mm² HORSE F.42 73-AL1/43-ST1A

10 Conductor ACSR Bare 100mm² DOG F.42 105-AL1/14-ST1A

11 Conductor ACSR Bare 150mm² WOLF F.42 158-AL1/37ST1A

12 Conductor ACSR Bare 150mm² DINGO F.42 159-AL1/9ST1A

13 Conductor ACSR Bare 175mm² LYNX F.42 183-AL1/43-ST1A

14 Conductor ACSR Bare 200mm² JAGUAR F.42 211-AL1/12-ST1A

15 Conductor ACSR Bare 400mm² ZEBRA F.42 429-AL1/56-ST1A

16 Conductor ACAR Bare 300mm² n/a n/a 213-AL1/124-AL3

11 of 13


Version: 04


Appendix B - Information to be provided by Supplier Type tests for Bare Aluminium Conductors (Table 5, BS EN 50182)

Manufacturer Conductor Designation Name Signature Date

Instructions for completion: • Complete a separate table for each conductor size and type • Manufacturer / Supplier to complete columns 6 to 10 inclusive

1 2 3 4 5 6 7 8 9 10Type Test No.

Test Requirement BS EN 50182 Clause

Rated Value or range

Test Required

Y/N

Conformance* Test Value Date of Test Test Station Report / Cert. No.

Remarks

Conductor

1 Surface Condition 6.4.1 Y

2 Diameter 6.4.2 Y

3 Inertness 6.4.3 Y

4 Lay ration and direction of lay 6.4.4 Y

5 Number and type of wires 6.4.5 Y

6 Mass per unit length 6.4.6 Y

7 Stress-strain curve 6.4.7 N

8 Tensile breaking strength 6.4.8 Y

9 Stringing test 6.4.9 N

Aluminium wires

10 Diameter 6.5.2 Y

11 Tensile strength 6.5.2 Y

12 Elongation (not for Al1 wires) 6.5.2 Y

13 Resistivity 6.5.2 Y

14 Wrapping Test 6.5.2 Y

15 Welding 6.5.3 Y

12 of 13


Version: 04


Appendix B – Information to be provided by Supplier (cont.)

1 2 3 4 5 6 7 8 9 10

Type Test No.

Test Requirement BS EN 50182 Clause

Rated Value or range

Test Required

Y/N

Conformance* Test Value Date of Test Test Station Report / Cert. No.

Remarks

Zinc-coated steel wires

16 Diameter 6.5.2 Y

17 Tensile Strength 6.5.2 Y

18 Stress @ 1% Extension 6.5.2 Y

19 Elongation or torsion test 6.5.2 Y

20 Wrapping test 6.5.2 Y

21 Mass of Zinc 6.5.2 Y

22 Zinc dip test 6.5.2 Y

23 Adhesion of zinc coating 6.5.2 Y

Grease

24 Mass per unit length 6.6.1 Y

25 Drop point 6.6.2 Y

* Conformance Declaration Codes

N/A = Clause is not applicable/ appropriate to the product Cs1 = The test conforms fully with the requirements of this clause Cs2 = The test conforms partially with the requirements of this clause Cs3 = The test does not conform to the requirements of this clause Cs4 = Test not performed, but alternative evidence / technical case offered

Ct1 = Independent witnessed tests Ct2 = Not fully independent witnessed tests Ct3 = Self verified tests Ct4 = Alternative tests / evidence offered Ct5 = Manufacturer has underwritten the product Ct6 = Not tested

13 of 13

Documents

ES 01-0500 Bare Aluminium Conductors for Overhead Lines[1]