1、 Aluminum Electrical Conductor Handbook THIRD EDITION 1989 the Incorporaiea Aluminum Association 900 19th Street, N.W., Washington, D.C. 20006 About the Aluminum Association The Aluminum Association is an industry-wide trade organiza- tion representing over 90 com- panies including most of the pri-
2、mary producers of aluminum in the United States, reading man- ufacturers of semi-fabricated alu- minum products and principal foundries and smelters. The Associations aims are to increase public and industrial understanding of aluminum and the aluminum industry and- through its technical, statistica
3、l, marketing and informational ac- tivities-to serve industries, con- sumers, financial analysts, educa- tors, students, government agen- cies and the public generally. For the aluminum industry and those industries that use alu- minum, the Association helps develop designation systems, codes and sp
4、ecifications involv- ing aluminum products and studies technical matters of interest to the industry. The Association maintains and periodically issues industry-wide statistics and records which are used as an authoritative source. Association members also join together on a number of com- modity an
5、d end-market commit- tees to conduct industry-wide market development programs. Aluminum Electrical Conductor Handbook Third Edition 1989 Larry Kirkpatrick, Editor The 1971 edition of this book was based both on text covering bare and insulated conductors written by Tracy W. Simpson, BSEE, EE, and o
6、n an original manuscript written by Eugene W. Greenfield, BE, MS, Dr. Eng., coordinated by John Knight, Publications Consultant. The 1982 edition was reviewed, revised, and rewritten under the direction of an Editorial Board drawn from the Aluminum Associations Electrical Technical Committee and oth
7、er industry personnel, and edited by Mark Walker, Electrical Consultant. Chapter 13 was wholly rewritten and revised by L. T. Guess (B.S., Elect. Eng., Mississippi State University; M.S. Elect. Eng., Purdue University), with more than 35 years experience in bus engineering de- sign and construction.
8、 Information and engineering data in the handbook were obtained from many companies throughout the electricity consuming, producing, and equipment industries, as wei as from individuals in the field. The 1989 3rd edition has been updated under the direction of Larry Kirkpatrick, Electrical Consultan
9、t. Mr. Kirkpatrick (BAS, Elect. Eng., University of British Columbia) has had 37 years experience in the electrical industry. He is a fellow of ASTM and a former member and chairman of the Aluminum Associations Electrical Technical Committee. In this edition, Chapter 4, “Product Identification and D
10、ata,” has been extensively revised, including an irn- proved layout of the tables and the addition of physical and electrical properties in the new shaped wire (TW) transmission conductors. Information on the 8XXX series alloys used for building wire has been included and data on alloy 5005 wire hav
11、e been deleted, since the latter product is no longer commercially available. Chap- ter 11 has been rewritten to present more up-to-date practices. Library of Congress Catalog NO. 81-71410 Aluminum Association Publication No. ECH-56 FOREWORD Aluminum electrical conductors today are being speci- fied
12、 for nearly all new transmission lines and for most bare overhead distribution lines. Covered and insulated aluminum wire and cable have also been widely accepted; it is estimated that almost all new service drops and service entrance lines are of aluminum. Aluminum now also has a significant share
13、of the insulated, interior wire market, particularly in the larger sizes where weight and ease of handling are important factors. Designers of heavy-current installations, particularly among electric power utilities and industrial users, have realized substantial energy savings through the use of la
14、rger conductors to cut I2R losses. Such savings are equally applicable to other conductor materials, but the time required to recover the extra conductor expense is an important consideration. The Electrical Conductor Handbook presents informa- tion regarding various aluminum alloys when fabricated
15、as electrical conductors - from standpoints of circuit design, installation, and maintenance. The major emphasis is on conductors for transmission, distribution, and utilization of electric power. Other important uses of aluminum by the electrical industry also are described. The book is written fro
16、m the viewpoint of the electrical application engineer, as distinct from that of an electrical engineer employed by a manufacturer to design wire and cable. Thus the description in Chapter 5 of the sag-tension chart tells principally how the application engineer pre- pares suitable charts for a prop
17、osed circuit. Another important objective of the book is to present the text so it may be understood by student engineers and those in utility training classes. To this end, many numerical examples are included. The numbering plan used in the book for pages, tables, equations, and illustrations ment
18、ioned in text comprises two numbers separated by a hyphen. The left- hand number is that of the chapter; the right-hand number is that of a table, equation, or illustration (Figure) in the chapter. Thus, Eq. 5-2 is the 2nd equation in Chapter 5. Similarly, Fig. 5-8 is the 8th mentioned illustration
19、in Chapter 5. Appendices follow the chapter to which each applies. Industry Standards (ASTM, NEMA, UL, ANSI, etc.) referred to herein are revised periodically; hence the latest edition of the Standard should be consulted. Standards listed herein that do not show year of issue are those applicable wh
20、en this book was approved for publica- tion. For a listing of Standards Organizations, including addresses, cited in this book, see next page. references Listing of Organizations Whose Codes, Standards, and Technical Papers Are Referenced in This Handbook Association of Edison Illuminating Companies
21、 (AEIC) 51 E. 42nd Street New York, NY 10017 American National Standards Institute (ANSI) 1430 Broadway New York, NY 10018 ASTM 1916 Race Street Philadelphia, PA 19103 Edison Electric Institute (EEI) 7111 19th Street N.W Washington, DC 20036 Electric Power Research Institute (EPRI) P.O. Box 10412 Pa
22、lo Alto, CA 94303 Insulated Cable Engineers Association (KEA) P.O. Box P S. Yarmouth, MA O2664 Institute of Electrical and Electronics EngineersdiEEE) 345 E. 45th Street New York, NY 1001.7 (National Electric Safety Code) National Electrical Manufacturers Association (NEMA) 2101 L. Street N.W. Washi
23、ngton, DC 20037 National Fire Protection Association (NFPA) Batterymarch Park Quincy, MA 02269 (National Electrical Code) Underwriters Laboratories, Inc. (UL) 333 Pfingsten Road Northbrook, IL 60062 Use of the information The data and suggestions contained in this publication were compiled and/or de
24、veloped by the Aluminum Associa- tion, Inc. In view of the variety of conditions and methods of use to which such data and suggestion may be applied, the Aluminum Association and its member companies assume no responsibility or liability for the use of information contained herein. Neither the Alumi
25、num Association nor any of its member companies give any warranties, express or implied, with respect to this information. All Aluminum Association published data, specifications, and other material are reviewed at least every five years and revised, reaffirmed, or withdrawn. Users are advised to co
26、ntact the Aluminum Association to ascertain whether the in- formation in this publication has been superseded in the interim between publication and proposed use. table of contents Section I Aluminurn - the Metal Chapter one Early and Present-Doy Processing Aluminum metal-working processes 1-1 seque
27、nce of fabricating operations treatment for improvement of physical properties temper designations Aluminum and aluminum alloys for electrical conductors 1-4 Anodizing 1-7 Other processes 1-7 Chapter two Aluminum Conductor Properties and Advantages The effect of alloying 2-1 Conductivity 2-1 Light w
28、eight. 2-2 Strength 2-2 Workability . 2-2 Corrosion resistance 2-3 Creep 2-3 Compatibility with insulation . 2-3 Thermal properties . 2-3 Section II Bare Aluminum Wire and Cable Chapter three Engineering Design aluminum wire gage stranded conductors concentric-lay stranding difference between strand
29、ed and solid conductors special conductor construction aluminum conductor steel reinforced (ASCR) and modifications aluminum conductor alloy-reinforced (ACAR) international annealed copper standard change of dc resistance with temperature temperature-resistance cmff icients for various temperatures
30、skin effect in steel-reinforced stranded conductors (ACSR, etc.) proximity effect hysteresis and eddy current effects radiation loss corona inductive reactance X, geometric mean radius (GMR) inductive reactance of bundled conductors zero-sequence resistance and inductive reactance shunt capacitive r
31、eactance X, zero-sequence capacitive reactance capacitive reactance of bundled conductors Mechanical design of conductors . 3-1 Composite conductors . 3-3 Calculation of de resistance . 3-7 Calculation of ac resistance 3-8 Inductive and capacitive reactance . 3-12 Ampacity of bare conductors 3-19 1
32、table of contents (continued) heat balance ampacity of 1350-Hl9 all-aluminum conductor and standard-strength ampacity of single-layer high-strength ACSR conductors ampacity 6201 -T81, and ACAR conductors ACSR conductors Chapter four Product Identification and Data Product classification of bare alum
33、inum conductors 4-1 Product identification . 4-1 for i 350 aluminum and temper AAC for ACSR, AAAC and ACAR size relationships technical data and catalog information List of tables in chapter 4. 4-3 Chapter five installation Practices Line design factors initial and final sag-tension charts for varia
34、ble-length spans initial stringing chart. . Therulingspan . completion of stringing graph by use of parabola formula sag correction for long spans Use of stringing charts . lhe sag-span parabola and template. . sag when supports are at different elevations unbalanced forces at support points lhe upl
35、ift condition (negative span) Preparation of sag-tension charts The catenary curve an preliminary sag-tension graph. . Method of drawing the parabola . The stress-strain graph initial and final sag and tension of a designated conductor, span and Sag-tension graphs for composite conductors . Overhead
36、 conductor accessories and fittings . NESC loading at various temperatures joints and connectors bolted clamp connectors welded connections dead-ends and dead-ends clamps suspension clamps tie wires armor rods Aluminum-to-copper connections Chapter six Operatina Performance and Problems 5- 1 5-4 5-4
37、 5-7 5-7 5-8 5-10 5-10 5-1 1 5-12 5-18 5-21 5-25 Short-circuit performance adjustments for 6201 -T81 and ACAR conductors adjustment for upper temperature limit Arcing . Arcing effects. . Loss of strength Fault-current electro-magnetic forces between parallel bare wires and cables. 6- 1 6-2 6-2 6-2 6
38、-9 2 table of contents (continued) Emergency loading . Vibration and fatigue of overhead conductors . aeolian vibration of conductors fatigue of conductor strands vibration dampers spacers and dampers for bundled conductors Section 111 Covered and Insulated Aluminum Wire and Cable Chapter seven Revi
39、ew of Types and Applications Conductors for use with covered or insulated wires or cables . The distinction between covered and insulated conductors . . Cavere aluminum line wires and cables . covered line wires tree wire spacer cable aluminum power and lighting insulated 600-volt cables Insulated c
40、onductors and cables (0-600 volts) . Single conductors (O to 600 volts) Aerial cable assemblies (O to 600 volts) parallel aerial cables (PAC) reverse twist secondary cables (RTS) service drop cables aluminum interlocked or seamless armored cables aluminum service-entrance cables (600-volt) aluminum
41、sheathed cables (600-volt) Multiple conductor power cables (O to 600 volts). Aluminum cables for underground installation (600-volt). . Insulated conductors (above 600 volts) power cables (above 600 volts) primary URD cables for underground residential distribution (5 kV to medium-voltage shielded s
42、ingle-conductor power cables (5 kV to 35 kv) interlocked-armor cables preassembled aerial cables (to 35 kV) aluminum pole-and-bracket cables for series street lighting aluminum mine power cables aluminum portable cables aluminum submarine cables special applications cables 35 kV) Aluminum insulated
43、conductors for special conditions Chapter eight Insulation and Related Cable Components Typical 3-conductor cable assemblies . Conductors for insulated cables Coverings for uninsulated conductors . Insulating materials and performance Thermosetting insulating materials styrene-butadiene synthetic ru
44、bber (SBR) butyl synthetic rubber cross-linked polyethylene insulation (XlPE,XHHW) 6-10 6-1 1 7-1 7- 1 7-2 7-2 7-2 7-2 7-3 7-4 7-4 7-5 8- 1 8-2 8-2 8-2 0-4 3 table of contents (continued) ethylene-propylene rubber (EPR) fluorinated ethylene propylene rubber (FEP) neoprene synthetic rubber asbestos i
45、nsulations (SA. AVA. AVL) thermoplastic polyvinyl chloride (PVC) thermoplastic polyethylene (PE) polyvinyl chloride jackets polyethylene jackets neoprene jackets nylon jackets nitrile-butadiene/polyvinyl-chloride jackets unipass jackets no iacket requirements insulating tapes shielding materials and
46、 shielding methods the effect of corona on insulation and shielding sheaths, fillers and binders insulation resistance water absorption temperature Thermoplastic insulating materials . 8-9 Jacket materials . 8-9 Tapes and shielding materials . 8-10 KEA performance specifications . 8-12 NEC designati
47、ons . 8-12 Appendix 8A Elements of Dielectric Theory. 8-13 charging current and leakage conduction current charging and leakage-conduction currents under direct and alternating total dielectric current and power factor under a-c conditions dielectric constant (L) under a-c conditions capacitance of
48、insulated conductors with grounded sheath or directly example of dielectric computation potential buried Chapter nine Engineering Design as Related to Cable Applications Cable diameter 9-1 Duct, conduit and raceway installations . 9-1 Cable-conductor resistance . 9-3 spacing between cables addc rati
49、os for aluminum cables general conditions applying to table 9-4 Cables in aluminum conduit . 9-6 Series inductive reactance. . 9-8 series-inductive-reactance calculation supplementary table for series inductive reactance reactance of conductors on rigid cable supports Shunt capacitive reactance . 9-9 Voltage-drop 9-12 Ampacity of insulated conductors 9-13 ampacity ratings emergency overload ratings short-circuits 4 table of contenSr (continued) Chapter. 9A Explanation of ICEA-IEEE tables of ampacity of insulated aluminum cables for var
