IEEE – VTS 2014

PROOF POSITIVE® CopperDesign Options:

• Solid ground conductors will focus on sizes #2, #4, #6 and #8 AWG. Packaging options will include 25‐pound (11.4 kg) and 50‐pound (23 kg) spools. Larger capacity reel packaging will also be available.

• The marked conductors use the same procedures as standard ground conductors, requiring no operational changes in installation, training or equipment.

Southwire revolutionized the world of aluminum in 1968. Southwire was the first to develop and patent aluminum alloy AA-8176, the first AA-8000 series aluminum alloy for all aluminum conductors used inside buildings. Southwire’s AlumaFlex® has been installed ever since and has always been manufactured to the highest quality of 8000 Series aluminum alloy. Today, with a proven track record of over 40 years, aluminum wire is just as safe and just as reliable as copper.

•Differential cost of $3.00/lb between copper and aluminum

10 Year Historical Graph of Copper & Aluminum Data

Profit – 0%

we don’t want to make money we just love to sell cable.

3c 15kV Shielded

60%Conductors20%

Insulation

Shields

12%Jackets Armor

Labor & Packaging – 8%

Manufacturing Costs – Power Cable

Example of Undesirable Materials Combination

DIFFERENCES IN THERMAL EXPANSION AND CREEP OF MATERIALS RESULTS IN:

• Rapid conductor deformation due to creep• Loss of mechanical load and connector degradation

Different Material and Thermal Expansions Lead to Undesirable Electrical Connections

0

5

10

15

20

25

Steel Brass Copper Aluminum

Coeffiecnt of Thermal Expansion

Definition of Thermal Expansion and Creep

CTE: The coefficient of thermal expansion is defined as the fractional increase in length per unit rise in temperature. Micro inches/inch oF

Creep: Is the measurement of the rate of change of a material’s dimension over a period of time when subject to a force at a particular temperature. Copper and AA8000 series aluminum have similar creep rates unlike EC 1350 which has a much higher creep rate than copper.

Conditions for a ReliableAluminum Electrical Connection

The aluminum conductor and connector alloys must have similar “creep-properties” to avoid loss of contact load and electrical degradation over a long service life

What Are The NEC Requirements for Al 600 and Medium Voltage Conductors?

• NEC 310-106 (B) (2011)– Aluminum conductors rated 600 volt shall be made of AA-

8000 series electrical grade aluminum alloy. – NEC does not address aluminum grade type for MV

cables

• Connectors:– UL 486B– Dual rated lugs for copper or aluminum

• Dual rated lugs are made of aluminum. Used on copper conductors

– mechanical or compression.

Aluminum AssociationAA8000 Series

• Alloy: – Traces of copper gives better thermal stability.– Traces of iron makes it more flexible.

• Anneal:– Aluminum is treated with heat to removes

internal stresses in the aluminum. Less brittle.

• How does an AA8000 series aluminum compare with copper?

Creep Loss % or Stress Relaxation kP

The creep properties of AA 8176 are comparable to annealed copper.

Conditions for a ReliableAluminum Electrical Connection

Typical example of a UL Dual-Rated connection Al-Cu,

Stranding

- Stranding: Class B most common

Stranding Constructions

- Concentric Round (Bare Conductors)

- Compressed (3% reduction)

- Compact (10% reduction)

Comparison of Copper andAluminum Conduit Fill, 600 Volt

Cu Size Amps EMT Size

Al Size Amps EMT Size

3/0 200 2 250 kcmil 205 2 1/2

4/0 230 2 1/2 300 kcmil 230 2 1/2

250kcmil 255 2 1/2 350 kcmil 250 2 1/2

350 kcmil 310 3 500 kcmil 310 3

500 kcmil 380 3 750 kcmil 385 3 1/2

600 kcmil 420 4 900 kcmil 430 4

Conduit Fill - Table C.1 (EMT); C.1A, 2011 NEC Annex C, 4 wire plus groundAmpacity – Table 310.15(B)(16) @75C; 30C ambient.

1/0 150 2 3/0 155 2

2/0 175 2 4/0 180 2

Comparison of Copper andAluminum Conduit Fill, 5kv

Cu Size Cu OD

Amps Rigid Size

Al Size Al OD Amps Rigid Size

1/0 1.08 195 3 4/0 1.19 230 3

2/0 1.12 225 3 4/0 1.19 230 3

4/0 1.22 295 4 350kcmil 1.35 310 4

350kcmil 1.38 395 4 600kcmil 1.56 395 5

500kcmil 1.50 480 5 750kcmil 1.66 485 5

750kcmil 1.76 585 5 1000kcmil 1.89 565 6

#2 .99 150 3 1/0 1.04 150 3

250kcmil 1.28 330 4 500kcmil 1.47 385 4

Conduit fill is based on 3 phase with equipment ground size per NEC.All Conduit Sizes are Metal RigidAmpacity based on Table 310.60(C)73 and 310.60 (C)74 conduit in air. 1000kcmil Al DOES NOT meet the ampacity of 750kcmil Cu.

Comparison of Copper andAluminum Conduit Fill, 15kv

Cu Size Cu OD

Amps Rigid Size

Al Size Al OD Amps Rigid Size

1/0 1.08 195 3 4/0 1.19 230 3

2/0 1.12 225 3 4/0 1.19 230 3

4/0 1.22 295 4 350kcmil 1.35 310 4

350kcmil 1.38 395 4 600kcmil 1.56 395 5

500kcmil 1.50 480 5 750kcmil 1.66 485 5

750kcmil 1.76 585 5 1000kcmil 1.89 565 6

250kcmil 1.28 330 4 500kcmil 1.47 385 4

#2 .99 150 3 1/0 1.04 150 3

Conduit fill is based on 3 phase with equipment ground size per NEC.All Conduit Sizes are Metal RigidAmpacity based on Table 310.60(C)73 and 310.60 (C)74 conduit in air. 1000kcmil Al DOES NOT meet the ampacity of 750kcmil Cu.

Copper and Aluminum Comparison for 600 volt

COPPER ALUMINUM

Impedance at 75C 60 Hz, 600 volt ohms/1,000’

4/0 : 0.067 + j 0.041 ; z = 0.078250kcmil: 0.057 + j 0.041 ; z = 0.070350kcmil: 0.043 + j 0.040 ; z = 0.058500kcmil: 0.032 + j 0.039 ; z = 0.048750kcmil: 0.024 + j 0.038 ; z = 0.040

Impedance at 75C 60 Hz, 600v ohms/1,000’

350kcmil: 0.066 + j 0.040 ; z = 0.077500kcmil: 0.048 + j 0.039 ; z = 0.061600kcmil: 0.041 + j 0.039 ; z = 0.055750kcmil: 0.034 + j 0.038 ; z = 0.0491000kcmil: 0.027 + j 0.037 ; z = 0.042

Source: Table 9 of NEC

Copper and Aluminum Comparison for 5 and 15kv

COPPER ALUMINUM

Heavier500kcmil strd: 1,544lb/1,000’

Lighter – 54% lighter750kcmil strd: 704lb/1,000’

Better Conductivity per size – dc Ohms500kcmil = .0216 ohms/1,000’

Aluminum – 61% Conductivity of Cu – dc Ohms 500kcmil = .0354 ohms/1,000’750kcmil = .0236 ohms/1,000’

Impedance at 75C 60 Hz in Magnetic duct 5 & 15kv ohms/1,000’4/0 : 0.0650 + j 0.0583 ; z = 0.0873250kcmil: 0.0557 + j 0.0570 ; z = 0.0797350kcmil: 0.0386 + j 0.0562 ; z = 0.0681500kcmil: 0.0300 + j 0.0526 ; z = 0.0605750kcmil: 0.0223 + j 0.0497 ; z = 0.0545

Impedance at 75C 60 Hz in Magnetic duct 5 & 15kv ohms/1,000’350kcmil: 0.0614 + j 0.0468 ; z = 0.0773500kcmil: 0.0435 + j 0.0444 ; z = 0.0624600kcmil: 0.0366 + j 0.0431 ; z = 0.0566750kcmil: 0.0298 + j 0.0419 ; z = 0.05141000kcmil: 0.0233 + j 0.0414 ; z = 0.0475

Source: IEEE 141 - 1993

Short Circuit Comparison

Short Circuit K amps at 30 Cycles

500 kcmil Cu 50 48 750 kcmil Al

4/0 Cu 21 23 350kcmil Al

Connection Preparation ForAluminum Conductors

Unused aluminum strand surfaces before brushing.

Unused aluminum strand surfaces after brushing.

• Disrupt surface contaminant films with steel brush

• Apply a recommended inhibitor to the conductor

• Mechanical Connectors: Torque the bolt to levels recommended by the manufacturer; excessive torque will deform the conductor and may lead to loss of strands. (this applies to aluminum and copper conductor.

• Compression Connectors: Use the proper tool and die depending on the connector size . Crimp according to the manufacturer recommendation.

Connection Preparation

Flexibility

• Alloying and annealing processes make AA-8176 as flexible for equivalent Ampacity copper conductors.

• NEC 321.6(B) requires the same bending space in enclosures at terminals for equal amapcity copper and AA-8176 conductors.

Bending Force for same Ampacity

250 Al 3/0 Cu 750 Al 500 Cu

128197.4

806748

Forc

e lb

s

XHHW

Pulling Tensions and Minimum Bending Radius

• AA 8176 aluminum has higher tensile strength to weight ratio than equivalent copper ampacity.

• Max allowable tensile tension for copper is 0.008 lbs/cmil and for AA 8176 is 0.006 lbs/cmil.

• Minimum bending radius for both aluminum and copper shielded multi-conductor cable is 7 times the overall OD of cable.

• 3/c 500kcmil Cu aia: 7 x 3.34” = 23.38”• 3/c 750kcmil Al aia: 7 x 3.77” = 26.39”

Pulling Tensions (Cont.)

Conductor Size Max Allowable Tension lbs

Weight lbs/1,000’

Max Pull Length (ft)

0.3 coef fric500kcmil Cu 4000 lbs 1544 8,639

750kcmil Al 4500 lbs 704 21,307

For any given route, the pulling tension on copper conductorcables will always be higher than the tension on equivalent ampacity aluminum conductor cable.

Short List of Aluminum Projects Savings

Project Quantity Year Cable Type Savings

Honda of AmericaDecatur, IN

28,00014,000

2007 3/c 750kcmil 15kv aia3/c 750kcmil 600v aia

$735,000

Bloomingburg Ethanol PlantBloomingburg, OH

16,00012,000

2008 1/c 750kcmil 5kv1/c 500kcmil 5kv

$110,000

Gastonia Water TreatmentConcord, NC

40,000 2008 1/c 350kcmil 5kv $120,000

General Motors – Toledo, Parma, Bay City, Pontiac, Lordstown

25,000 2007, 2011

3/c 750kcmil 15kv aia $580,000

Chrysler – Marysville, MI 60,000 2008 3/c 750kcmil 600v TC $1,600,000

Chrysler – Belvedier, ILChrysler – Sterling Hts, MIChrysler – Kokomo, IN

80,00050,00040,000

2011, 2012

3/c 750kcmil 600v aia3/c 750kcmil 600v aia3/c 750kcmil 600v aia

$4,500,000

MV Power Cable Schematic

Applications: Used to distribute power to: pumps, presses, motors, lightingand control circuits etc. in: pulp & paper mills, steel mills, processing plants,commercial centers, mines, generating stations, refineries, industrial plantsand chemical plants.

Conductor

Insulation Shield

Metallic Shield

Conductor ShieldInsulation

Jacket

Flexibility

QUESTIONS?Thank you

Cable in Conduit for Direct Burial• Schedule 40 & Schedule 80 HDPE ( UL Approved )

• Sizes ½”– 6”

• Southwire conduit fill app

Southwire® Order Tracker Southwire’s Order Tracker app allows the user to view order shipments, including line status and carrier information. 

SIMpull® 600V Calculator The SIMpull® 600V Calculator provides multiple calculators within a single app that are connected by specific wire pull characteristics (i.e. Voltage Drop, Ground Wire Sizing, Phase Wire Ampacity, Phase Wire Attributes, Sidewall Tension/ Pressure and Reel Sizing) and generates individual NEC® compliant answers. Results are easily emailed. 

SIMpull Solutions® Configurator Allows users to load a wire feeder schedule following a step by step process that will build paralleled runs with SIMpull Head® pulling grips. Users can then stack like runs or different runs on a reel and see accurate weight and reel size dimensions 

Voltage Drop Provides multiple calculations and will help you determine the proper wire size for an electrical circuit based on the voltage drop and current carrying capacity of an electrical circuit 

Conduit Fill Answers the question: "What size conduit do I use with fill percentage and jam probability." per the NEC®. Results can be emailed 

Proof Positive© Copper Southwire’s Proof Positive® Copper app helps to track your stolen wire. After Proof Positive® Copper has been stolen, enter the license key and serial number from the recovered wire. The current owner and chain of ownership will be displayed on the owners 

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