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Disclosure to Promote the Right To Information

Whereas the Parliament of India has set out to provide a practical regime of right to

information for citizens to secure access to information under the control of public authorities,in order to promote transparency and accountability in the working of every public authority,

and whereas the attached publication of the Bureau of Indian Standards is of particular interest

to the public, particularly disadvantaged communities and those engaged in the pursuit of

education and knowledge, the attached public safety standard is made available to promote the

timely dissemination of this information in an accurate manner to the public.

!"#$% '(%)

!"# $ %& #' (")* &" +#,-.Satyanarayan Gangaram Pitroda

Invent a New India Using Knowledge

/0)"1 &2 324 #' 5 *)6Jawaharlal Nehru

Step Out From the Old to the New

7"#1&"8+9&"), 7:1&"8+9&")Mazdoor Kisan Shakti Sangathan

The Right to Information, The Right to Live

!"# %& ;

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IS 398 P ~ ~ ) , = i : - . ~ ~ ~ LRE; .... : . P o:L

Indian StandardALUMINIUM CONDUCTORS FOR OVERHEADTRANSMISSION PURPOSES SPECIFICATION

PART 2 ALUMINIUM CONUUCTORS GALVANIZED STEEL REINFORCED

Third RevisionSecond Reprint OCTOBER 2001

ICS 29.240.20

\) HIS 1996URE U OF IN I N ST ND RDSMANAK BHAY AN. l} BAHADUR SHAH ZAFAR MARG

NEW DELHI 110002[)(,(,C fII Jcr 1996 Price Group 5

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AMENDMENT NO. 1 MARCH ITOIS 3.(PART 2) : I ALUMINIUMCONDUcrORSFOROVERHEAD TRANSMISSION PURPOSES-SPECIDCATIONPART ALUMINIUM CONDUCTORS GALVANIZED

STEEL REINFORCEDTlainl RnisiOll

( Pilge S, clause 13. , (vst fN ra formuls ) - Substitute the following {orthe existing:R20= RT l+oc T-20

wbereR10= resistancecorrected at 20C;RT resistance measured at roC;QC =constant mass tempenture co-efficlent of resistance 000403; andr =ambieat temperature duringmeasurement.6, lt ue 14.1(b)and(c) ]- Insed superscript1) at both tbe places.(PIIge 8, Table 3, col2, row12 ) - Substitute 5413 53 lor 54/4.13( Page 8, Table S, Heading) - Substitute Strandlag Constants lorStaadlill Constants .(Pllge 8, Table S,col2, row1) - Substitute 1 for 0 .

ET37)

Repropap.y Ulia. 81S. NewDel IDdia

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AMENDMENT NO. 2 MARCH 2000TOIS 3 8 PART2) : 1 ALUMINIUM CONDUCTORSFOR OVERHEAD TRANSMISSION PURPOSES SPECIFICATIONPART 2 ALUMINIUM CONDUCTORS GALVANIZEDSTEELREINFOR E

TAW RnUion)(Pllge2 clt usc . 1.1 ) - SUbititute 5484: 1997 for 5484 : 1978 .Page2, cl usc , .2.2) - Delete andrenumber tbe subsequent clauses. Page2, clause .13 ) - Deletesubheading Conductor COlllainillgMoreTha SevenWiresPage 2, clause .2.3,rlrstsentence) - Delete For stnnded conductorcontainingmorethan sevenwires .

(Page 3, clause 11.1 ) - Substitute S 1778 : 1980 for IS 1778 : 1981 . Page 3, clause lZ.l(c) and d - Substitute Net mass and Gross massfor Net weight and Gross weight respectively.Page3, claus 13.1.5,partl 1 ) - Delete last line. Page S, clause 13.6 ) - Substitute 0.004 03 for 0.004 for

description of X . Page5, clause13.9,para 1 ) - Substitute tbe following for tbe existing:

This tT t is applicable to conductors of nominal aluminium llel greater tbantOOmm. (Page S.clause13.10. para 1 ) - Sub st it ut e the f ol lo wi ng for tbe e xi st in g:

I This is applicable to conductors of nominal aluminium area grater thanI l00mm .Pale S, clause 13.10, IlISt w li ) - Substitute the following for theexiitilll:

The actull breakiDl load falls below the specified blaking Itleagthrequirement.1

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Amend No.2 to IS 3M Paat 2) : 1Page 5, cla 13 11 para1)- Substitutethe following for theexisting:

This testis to be conducted if agreedbetween the purchaser andsupplier .Page 6, cl use 13 11 3 6 llIIlliIIe - Substitute 13.11.3.2 5.3.5 . ge 6, cl use 13.11.5, line3 ) - Delete tbe word and after 70 percent .Page 6, cia 13.11.5) lnaert the followiug p i l i in the end:For the purpose of calculating stress-shain dati at 20C, the followingformula lI y be used:

12 . x 1+ 1-20

where2 is the ~ . .tlin valueatIJ0C,andt at roomtempellture.

[ ge 6, cl use 14.1 a) ) - Delete I and the corresponding footnote.

Em37

ph UIIII SIS,NewDel........2

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AMENDMENT NO. 3 DECEMBER 2002TOIS 398 PART2 : 1996 LUMINIUM CONDUCTORSFOROVERHE D TR NSMISSION PURPOSE SPECIFIC TIONPART 2 ALUMINIUM CONDUCTORS GALVANIZED STEEL REINFORCED

7Iltr l RnllltHlI Pale clau,. 13.6 lee GI o mellllmellllNo tUUl2 ] - Delete the

matter in the mendmentNo.2.I Pa 6, claus.tc.l b tUUl c n /QOtMI. lee lso merul MntsNo 1 and 2 ] - Delete the superscript 1 at both the places and thecorresponding footnote~ 3 7 Repropapby UBit 81S NewDelbi lDdla

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Conductors and Accessories for Overhead Lines Sectional Committee. ET 37

FOREWORD

This IndianStandard Third Revision) was adopted by the Bureauof Indian Standards, after the draft finalizedby the Conductors and Accessories for Overhead Lines Sectional Committee had been approved by theElectrotechnical Division Council.This standard was originally published in 1953, the first revision was brought out in 1961.In this revision, the standard had been modified in the light of the modern development in the techniquesof the conductor manufacture. The other salient point incorporated in this revision was the inclusion ofwrapping test for the aluminium wires in place of the elongation test originally specified for aluminiumas well as steel wires. The second revision was brought out in 1976 and the third revision has been undertaken with a view toeffecting the following considerations:

a) To line up with the International Standards.b) All amendments approved and circulated after 1976 have been considered while preparing thisstandard for third revision.c) The most important consideration bas been taken regarding improvement in conductivity of egrade aluminium, the maximum resistivity of 0.028 264 ohm. mm mm at 200C as per IEC Standard.d) Measurement of wire diameter, lay ratio, test procedure and testing of routine tests and acceptancetests have been included.e) Type tests have been included.

While revising this standard, it was decided to issue it in differentparts coveringdifferent types of conductors.This part dealing with galvanized steel-reinforced aluminium conductors fonn Part 2 of the series. Otherparts in this series are given below:

Part Part 3Part Part 5

Aluminium stranded conductorsAluminium.conductors, aluminized steel-reinforcedAluminium alloy stranded conductorsAluminium conductors, galvanized steel-reinforced for extra high voltage 400 kV and above .In the preparation of this standard, assistance has been derived from the following:

lE e 888: 1987 Zinc coated steel wires for stranded conductors.l 889: 1987 Hard drawn aluminium wire for overhead line conductors.lEe 1089: 1991 Round wire concentric lay overhead electrical stranded conductors.s 215 : Part2 : 1970Specification for aluminium conductors and aluminium conductors. steel-reinforced

for overhead power transmission: Part 2 Aluminium conductors, steel-reinforced. British StandardsInstituuon.The value of modulus of elasticity and coefficient of linear expansion are given in Annex B for information.For the purpose of deciding whether a particular requirement of this standard is complied with, the finalvalue observed or calculated, expressing the result of a test or analysis. shall be rounded off in accordancewith IS 2 : 1960 Rules for rounding offnumerical values revisedy The numberof significantplaces retainedn the rounded off value should be the same as that of the specified value in this standard.

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IS 398 Part Z : 1996Indian Standard

ALUMINIUM CONDUCTORS FOR OVERHEADTRANSMISSION PURPOSES - SPECIFICATIONPART ALUMINIUM CONDUCTORS GALVANIZED STEEL-REINFORCED

hird RevisionIECTION 1 GENERAL

1 SCOPE1.1 This standard Part 2 covers the requirementsand tests for aluminium conductors, galvanizedsteelreinforced used for overhead power transmissionpurposes.2 REFERENCES

1.3 DlretIIoa ef LayThe direction of lay is defined as right-hand or Jeft-hand. With right-hand lay, the wires conform to thedirection of the central part of the letter Z when theconductor is held vertically. With left-hand lay, thewires conform to the direction of the central part ofthe letter S when the conductor is held vertically.3.4 Lay Ratio

2.1 The following Indian Standards are necessaryadjuncts to this standard.

1885 : Electrotechnical vocabulary: Part 32Part 32 1993 Electric cables first revision

3 TERMINOLOGY

IS No209 : 19921778: 1980

4826: 1979

5484 : 19787623 : 1993

TitleZinc ingot fourth revisionReels and drums for bare wire firstrevision

Hot dipped galvanized coating onround steel wires first revisionBe grade aluminium rod producedby continuous casting and rollingLithium base grease for industrialpurposes second revision

Ratio of the axial length of a complete turn of thehelix formed by an individual wire in a strandedconductor to. the external diameter of the helix4 PHYSICAL CONSTANTS FORHARD-DRAWN ALUMINIUM4.1 ResistivityThe resistivity of aluminiumdepends upon its purityand physical condition. For the purpose of thisstandard, the maximum value permitted is 0.028 64ohm mm2/m at 20C and this value has been usedfor calculation of the maximum permissible valuesof resistance.

NOTE- It IS not Intended to check the resisnvuy from themeasured values of resistance.4.2 DensityAt a temperature of 20 D the density of hard-drawnaluminum has been taken as 2.703 g1cm .

3.0 For the purpose of this standard, the followingdefinitions, inaddition to those given in IS 1885Part32 : 1993 shall apply.3.1 Aluminium Conductor Galvanized SteelRelnforeedConductor consisting of seven or more aluminiumandgalvanizedsteelwiresbuilt up inconcentriclayers.The centre wire or wires are of galvanized steel andthe outer layer or layers of aluminium.3.1 DiameterThe meanof two measurements at right angles takenat the same cross section.

4.3 Constant-Mass Temperature Coefficient orResistanceAt a temperature of 20C the constant-masstemperature coefficient of resistance of hard-drawnaluminium, measured between two potential pomtsrigidly fixed to the wire, the metal being allowedto expand freely. has been taken as 0.004 03 D4.4 Coemcient of Linear ExpansionThe coefficient of linear expansion of hard-drawnaluminium at 0 C has been taken as 23.0) 101CThis value holds good for all practical purposes overthe range of temperature from 0 C to the highestsafe operating temperature.

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IS 398 Part 2) : 1996S PHYSICAL CONSTANTS FORGALVANIZED STEEL WIRES5.1 DensityAt a temperature of 20C, the density of galvanizedsteel wire is to be taken as 7.80 g1cm5.2 Coemcient at Linear ExpansionIn order to obtain uniformity in calculation, a valueof 11.5x 10 /oC may be taken as the value for thecoefficient of linear expansion of galvanized steelwires used for the cores of steel-reinforcedaluminiumconductors.

SE TION 2 M TERI LS6 MATERIAL6.1 The conductorshallbe constructed of hard-drawnaluminium and galvanized steel wires which havethe mechanical and electrical properties specified inTables 1 and 2.6.1.1 The Ee grade aluminium rods for use in themanufacture of aluminium wires shall conform to IS5484: 1978.6.1.2 Galvanized steel wire should be drawn fromhigh carbon steel rods produced by either acid orbase open hearth process, electric furnace or basicoxygen process. The mechanical properties of wireshall complywith the requirements given in Table 2.The chemical compositions of high carbon steel wireis given in Annex C for the purpose of guidance.6.2 The zincusedforgalvanizing shallbe electrolytehigh grade zinc not less than 99.95 percent purity.It shall conform to and satisfy all the requirementsof IS 209: 1992.The coating on the galvanized steel wires may beapplied by the hot processor the electrolyticprocess.When specified by the purchaser, neutral grease maybe applied between the layers wires.63 When specified by the purchaser, neutral greasehas to be applied as per one of the following cases:

a Steel core only,b) All conductor except outer layer,c) All conductor including outer layer, andd) All conductorexceptouter surfaceof thewiresin the outer layer.NOTE- Luhium soap grease corresponding to Grade IIof IS 7623 199:\ haVing mmunum drop point not lessthan 180 C is suitable for such application,

7 FREEDOM FROM DEFECTS7.1 The wires used for standard conductor shall besmooth and free from imperfections, such as spillsand splits.

2

SE TION 3 DIMENSIONS ANDONSTRU TION8 STANDARD SIZES8.1 Wires8 Nominal SizesTIle aluminium and galvanized steel wires for thestandard constructions covered by this standard shallhave the diameter specified in Tables I and 2. Thediameterof thegalvanized steelwireshall bemeasuredover the zinc coating.8.2 Aluminium Conductors, Galvanized SteelReinforced8.2.1 The sizes of stranded aluminiumconductors, galvanized steel-reinforced shall be asgiven in Table 3.8.2.2 The resistance shall be in accordance withTable 3. The mass excluding the mass of grease,if applied) are given in Table 3 for information.9 JOINT IN WIRES9.1 The wires shall be drawn in continuous length,without joints, except those made in wire rod orbefore drawing operation.9.2 Joints in Aluminium Stranded Wires9.2.1 During stranding in aluminium wire no weldsshallbemadefor thepurposeof achieving the requiredconductor length.9 2 2 Conductor Containing Seven Wire \Joints in wires other than those permitted under 9.1shall not be permitted in any wire of strandedconductor containing seven wires.9 2 3 Conductors Containing More Than Seven WiresFor stranded conductor containing more than sevenwires, joints are permitted in wire broken duringstranding provided such breaks are not associatedwith either inherently defective wire or with thoseof short lengths of aluminiumwires. Joints shall bedressed smoothly with a diameter equal to that ofparent wires and shall not be kinked. No two jointsother than those in wires before stranding permittedunder 9.1 occur at points in the stranded conductorsnearer than 15 In9.2.4 Joints shall be made by electric butt welding.electric butt cold upset welding or cold pressurewelding.These jomts shall be made in accordancewith good commercial practice.Electric butt weldingshall be annealed for approximately 250mmon bothsides of the welds,9.2.5 While the joints specified are not required tomeet the requirements of unjointed Wires they shall

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be withstandinl a stress of not less than 75 MPa forannealed electric butt wel4ed jointsand notlessthan130 MPaforcoldpressure andelectric buttcoldupsetwelded joints. The manufacturer shall demonstratethat the proposed welding method is capable ofmeeting the specified strength requirements.9.3 Jolatl In J}alvaaIIed st l WinsI INojoints of any kind shall be made in the finishedcoated steel wires.10 STRANDlNG

10.1 The wires used in the ~ n s t r u t i o n of agalvanizedsteel-reinforced aluminiumconductorshall,before stranding, satisfy all the relevant requirementsof this standard.lQ.Z The lay ratio of the different layers shall bewithin the limits given in Table 4. .. 10.3 The ratio of the nominal j ~ m e t e r of thealuminium wires to the nominal diameter ofthe galvanized steel wires in any particularconstructionofgalvanizedsteel-reinforced aluminiumconductor, shall conform to the appropriate valuegiven in Table 4.10.4 In all constructions, the successive layers shallhave opposite directions of lay, the outermost layerbeing right-handed.The wires in each layer shall beevenly and closely stranded. .10.5 In conductors having multiple layers ofaluminium wires. the lay ratio of any aluminiumlayer shall be not greater than the lay ratio of thealuminium layer immediately beneath it.10.6 Steel wires shall be formed during strandingso that they remain intact when conductor is cut forjomting operation,11 LENGTHS AND VARIAnONS IN LENGTHS11.1 Unless otherwise agreed to between thepurchaser and the manufacturer, galvanized steelreinforced aluminium conductor shall be supplied inthe manufacturer s usual production lengths and witha permuted variation of 5 percent jn the length ofanyone conductor length.11.2 Random LeolthsUnless otherwise agreed to between the purchaserand themanufacturer, it shall be permissibleto supplynot more than 10 percent of the lengths on anyoneorder In randomlengths;none of themshallbe shorterthan one-third of the nominal length.

SE TION 4 P p ~ I N AND ~ R K I N12 PACKING AND MAltK1NG1.2.J TIle conductorshall bewoundon reelsor drums

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IS 398 Part 2) : 19M13.2 Mea.uremeDt 01 Diameter 01 ladlvldualAluminiulD Wires and Galvanized Steel WiresOne sample cut from each of samples taken under13.1.1 and 13.1.2 shall be measured using amicrometer havingflat surface on both the anvil andthe end of the spindle 0 be read with micrometer.The diameter in millimetre shall be averageof threediametermeasurements eachof whichis theaverageof the maximum reading at a point taken near eachend and in the centre of the sample.The diameter of the wire shan be within the limitas specified in Tables 1 and 2.13.3 BreaklDI Load TestThis test shall be made on both aluminium andgalvanized steel wires.13.3.1 The breaking load of one specimen cut fromeachof the sampletaken under 13.1.1or 13.1.2shallbe determined by means of a suitable tensile testingmachine. The load shall be applied gradually andtherateof separation of thejawsof thetesting machineshall be not less than 25 mm/min and not greaterthan 100 mm/min.The ultimate breaking load of the specimens- shallbe not less than the appropriate value specified inTables I and 2.13.4 Ductility TestThis test shall be made on galvanized steel wiresonly by any of the procedures given in 13.4.1and 13.4.1. 3 4 Torsion TestOne specimen cut from each of the samples takenunder 13.1.1 (I 13.1.1 shall be gripped at its endsin two vices one of which shall be free to movelongitudinally during the test. A small, tensileload not exceeding 2 percent of the breaking loadof the wire shall be applied to the sample duringtesting. The specimen shall be twisted by causingone of the vices to revolve until fracture occursandthe numberof twists shall be indicated by a counteror other suitable device. The rate of twisting shallnot exceed 60 rev/min.Thetestmaybecarriedoutongaugelength I Jl lrnfor all wire sizes when the number of twists whichthe wire shall withstand shall be direct ratio to thenumbers specifiedfor 100 times the diameterof thewires.Whentested beforestranding the numberof completetwists before fracture occurs shall be not less than18 on a length equal to times the diameter ofthe wire.The primary fracture ~ h l l show. a smooth surfaceat ri ht angles to the axis of the wire. Any secondaryfracture shall be ignored.

4

NOTS - Portwoormen frIct oc:aaNdduriD.lWildna.die filii fract would be c a ed primaryfrIIdure aad diesublequent frac:hnawouldbe called 1eCOIIdarY frIcruJeI.

When telted after strandin the numberof completetwists before fracture occun shan be not less dian16 on a length equal to 100 times the diameter ofthe wire. Tbe fracture shall show a smooth surfaceat right angles to the axis of the wire. 3 4 2 Elongation T ~ s tThe elongation of one specimen cut from each ofthe samples taken under 13.1.1 ( I 13.1.2 shall bedetermined. The specimen shall be straightened byhand and an original gauge length of 200 mm shallbe marked on the wire. A tensile load shall beapplied as described in 13.3.1 and the elongationshall be measured after the fractured ends have beenfitted together. If the fracture occurs outside thegauge mark, or within 25 mm of either mark andthe required elongation is not obtained the test shallbe disregarded and another test made.When tested before stranding the elongation shallbe not less than 4 percent. When tested afterstranding the elongation shall be nbt less than 3.5percent.

NOTE - The sample has 10 passeither the torsion tell orelonption test thaiis if the conductor is pOllina any of thetwo tests the sample should be col1lidered passin .13.5 Wrappinl Tad...This test shall be made on both aluminium andgalvanized steel wires. 3 5 Aluminium WiresOne specimen cut from each of the samples ofaluminium wire taken under 13.1.1 and shallbewrapped round a wireof its owndiameterto forma close helix of eight turns. Six turns shall then beunwrapped and again closelytwrapped in the samedirection as before. The wire shall not break. 3 5 2 Galvanized Steel WiresOne specimen cut from each of the samples ofgalvanized steel wire taken under 13.1.1 cr 13.1.2shall be wrapped round a mandrel of diameterto 4 times the wire diameter to fonn a close helixof 8 turns. Six turns shall then be unwrapped andagaincloselywrapped in thesamedirectionas before.The wire shall not break.13.6 Resistance TestThis test shall be made on aluminium wires takenbefore stranding or after strandin.

NOTE - The resistance of individUli wi-a 1be .uch il lthe completed IlrudecI conductor meeII Ihe_Ie ofthe maximum rai.tance specified in Tlble 3 calcu byapplyinl the relevant strandin. co liven 1ft Table

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where

13.7 Galvanizing Test

resistance corrected at 20C;resistance measured at T C;

13.11.2.2 The distance between the clamp and thesleeve mouth shall be monitored with callipers duringthe test to ensure that. after the test. it does notchange by more than I mm 0.1 from the valuebefore the test.

This test is applicable to conductors of nominalaluminum area mm and above.13.11.1 This test is contemplated only to collect thecreep data of the conductor from the supplier. Asample of conductor of minimum 10 m length shallbe suitably compressed with dead end clamps.13 11 2 Test Set up13.11.2.1 The test sample shall be supported in atrough over its full length and the trough adjustedso that the conductor will not be lifted by more than10 mm under tension. This shan be ascertained byactual measurement.

IS 398 Part 2 : 1996A sample of conductor of minimum S m lengthsuitably clamped either end. The load shall beincreased at a steady rate up to rated ultimate breakingload and held for one minute. When so tested, theconductor shan not show any fracture. The appliedload shall then be increased until the failing load isreached and the value recorded. A re-test up to atotal of three tests, may be made if wire fractureoccurs ~ i t i n one centimetre of the end fittings andthe tensile strength falls below the specified breakingstrength requirement.13.11 Stress-Strain Test

13.11.2.3 The conductor strain shall be evaluatedfrom the measured displacements at the two ends ofthe gauge length of the sample. The gauge referencetargets shall be attached to the clamps which lockthe steel and aluminium wires together. Target platesmay be used with dial gauges or displacementtransducers and care shall be taken to position theplates perpendicular to the conductor. Twisting theconductor, lifting it and moving it from side-to-sideby the maximum amounts expected during the testshould introduce not more than 0.3 mm error in thereading.13 11 3 Test Loads for Complete ConductorThe loading conditions for repeated stress-strain testsfor complete conductor shall be as follows.13.11.3.1 I kN load shall be applied initially tostraighten the conductor. The load shall be removedafter straightening and then the strain gauges are tobe set at zero tension.13.11.3.2 For non-continuous stress-strain data, thestrain readings at I kN intervals at lower tensionsand S kN intervals above 30 percent of ultimatebreaking load shall be recorded.13.11.3.3 The sample shall be reloaded to SOpercentof ultimate breaking load and held for I h. Reading

s

I - X (T - 20)

constant-mass temperature coefficient ofresistance. 0.004; andT = ambient temperature during measurement.

The resistance corrected at 20C shall be not morethan the maximum value specified in Table I.

The electrical resistanceof one specimenof aluminiumwire cut from each of the samples taken under 13.1.1l 13.1.2 shall be measured at ambient temperature.The measured resis tance shall be correc ted to theva lue at 20 OC by means the formula:

This test shall be made on galvanized steel wiresonly.13.7.1 This test shalt be made on one specimen cutfrom each of the samples of the galvanized steelwires taken under 13.1.1 r 13.1.2.13.7.2 The uniformity of galvanizing and the weightof coating shall be in accordance with IS 4826: 197913.8 Measurement of Lay RatlolDirection ofLayThe lay ratio of each layer of the conductor shanbe measured and checked as per the requirementsspecified in Table 4, 10.5 and lay direction shan beas per requirement of 10.4.13.9 Surface Condition TestThis test is applicable to conductors of nominalaluminium area 100 mm and above.A sample of the finished conductorhavinga minimumrecommended length of S m with compression typedead end clamps compressed on both ends in sucha manner as to permit the conductor to take its normalstraight line shape, shall be subjected to a tensionof percent of the ultimate breaking load of theconductor.The surface shan not depart from its cylindrical shapenor shall the strands move relative to each other soas to get out of place or disturb the longitudinalsmoothness of the conductor. The measured diameterat any place shall not less than the sum of theminimum specif ied diameter of the individualaluminium and stee l strands as indicated in Tables Iand 2 of this standard.

This test is applicable to conductors of nominalaluminium area 100 mm and above.

13.10 Test lo r Ult imate Breaking Load onStnaded Coaductor

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IS _ Part 2) : 1are to be noted after lO, 15, 30. 45 nd 60 mindurinl the hold period. he load shall be mleuedfter the hold period.13.11.3.4 RelOldinl up to 70 percent of ultimatebreakinl load hIIbedoneand eld for I h.lteadin,.are to beno e fter 5. lQ. 5, 30,45and 60min he load .hall then released.

13.11.3.5 Reloadin. up to 85 percent of ultimatebreakinlload shall be doneandhe d for I h. Readin,are to be notedafter 10, 15,30,45 and 60minutesand then load shall be released. I13.11.3.6 Tension shall be applied a,ain and shallbe increased u n i f o r m l ~ .until the actual ~ r e a k i ~ 1- stren.th is reached. Simultaneous readlnls oftension and elongation shall be recorded up to 90percent of ultimate breakins load at intervalsdescribed under 1.3.5.13.1l.4 T ~ s t Ltx.uls for S t ~ Cor OnlyThe loading condition of repeated stress-strain testsfor the steel core of ACSR shall be as follows.13.11.4.1 The test shall consist of successiveapplication of-load applied in a manner similar tothat for the complete conductor at 30 percent, percent 70percentand8Spercent of ultimate breakingload.13.11.4.2 The steel core shall be loaded until theelongation at the beginnin, of each hold periodcorresponds tothatobtained on thecomplete conductorat 30 percent, SO percent 70 percent and 8S percentof ultimate breaking load respectively.13.11.5 Stress Strain CurvesThe design stress-strain curve shall be obtained bydrawing a smooth curve through the 0.5 and 1 hpoints at 30 percent, percent and 70 percent and ultimate breakinlload loadings. The stress-straincurvesshall be submitted to the purchaser alongwithtest results. The stress-straln data obtained duringthetest shall be corrected to the standard temperaturethat is 20 C.14 CLASSIFICATION OF TESTS14.1 Type Tests

a) Surface condition test see13.9b) Test for ultimate breaking load on strandedconductor see13.10

Apphcable for conducton DOlnlnw AlumlRluln Area 100mmond above

6

c) Stress-strain test (13.11),d) Mouuremcnt of diameter of individualaluminium and sJeel wires l ~ . J ~e) Meuurement of lay ratio (13. ),f Breakinl load of individual wires (13.3.1),,) Ductility lest (13.4),\h) Wrapping test (13.5),j) Resistance test t 3 . ~ ) , andk) Oalvanizina test (13.7).I

14.2 c c e p t ~ e Testsa) Measurement of diameter of individualaluminium and steel wires 13.2b) Measurement of lay ratio see 13.8 ,c) Breaking load of individual wires see

1 ~ . 3 . 1 ) .d) Ductility test see 13.4e) Wrapping test see13.5 ,t Resistance test see13.6), andg) Galvanizing test see 13.7).

14.3 Routine TestThe routine tests shall be done same as acceptancetests and shall be carried out before and afterstranding.15 REJECTION AND RETESTS15.1 Shouldanyone of the test pieces first selectedrail to pass the tests, three further samples from thesame batch shall be selected, one of which shall befrom the length fromwhich the original test samplewas taken. unless that length has been withdrawnby the supplier.15.2 Should all of the three test pieces from theseadditional samples satisfy the requirements of thetests, the balch represented by these samples shanbe deemed to comply with the standard. Should thetest pieces from any of the three additional samplesfail the balch represented shall be deemed not tocomply with the standard,

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IS 398 Part 2) 1996SECTION 6 TABLES

Table 1 Aluminium Wires Used in the Construction of Aluminium Conducton,Galvanized Steel-ReinforcedClauses 6.1, 8.1.1, 8.1.2.1, 13.2, 13.3.1., 13.5.1 and 13.6Diameter Cross Sectional Mass Resistance Breaklnl Load,Area of Nominal -c illA Diameter Wire A

rNominnl Min ,. Before After .Stranding StrandingI) 2 3 4 5 6 1 8)

mm mm mm mm kg/kin Ohrnsrkm kN kN1.50 1.48 1.52 1.767 4.78 16.432 0.32 0.301.96 1.94 1.98 3.017 8.16 9.561 0.54 0.512.11 2.09 2.13 3.497 9.45 8.237 0.63 0.602.59 2.56 2.62 5.269 14.24 5.490 0.89 0.853.00 2.97 3.03 7.069 19.11 4.079 1.17 1.113.18 s.is 3.21 7.942 21.47 3.626 1.29 1.23s s 3.32 3.38 8.814 23.82 3.265 .1.43 1.363-.50 3.46 3.54 9.621 26.01 3.006 1.55 1.473.S3 3.49 3.57 9.787 26.45 2.954 1.57 1.493.80 3.76 3.84 11.34 30.65 2.545 1.80 1.114.09 4.05 4.13 13.14 35.51 2.194 2.08 1.984.13 4.09 4.17 13.40 36.21 2.151 . 2.13 2.024.72 4.67 4.77 17.50 47.30 1.650 2.78 2.64

NOlE - The resistance has been calculated from the maximum value of resistivity and the cross sectional area based onthe minimum diameter.

Table 2 Steel Wires Used in the Constructten of Aluminium Conductors,Galvanized Steel-Reinforced lauses 6.1, 8.1.1, 13.2 and A-3.2Diameter Cross Sectional Ma.u Breaking Load,

Area of Nominal inDiameter Wire Nominal i X Before After

/ \ Stranding Strandingr I) 2 3 4 S 6 7rnm mm mm mm kg/kin kN kN

1.47 1.53 1.767 13.78 2.46 2.341.57 1.60 1.936 15.10 2.70 2.571.96 1.92 2. ) ) 3.017 23.S3 4.20 3.992.11 2.07 2.15 3.497 27.27 4.60 4.372.30 2.2S. 2.35 32.41 5.46 5.192.59 2.54 2.64 5.269 41.09 6.92 6.57l.OO 2.94 3.06 7.069 55.13 9.29 8.833.18 3.12 3.24 7.942 61.95 10.43 9.913.35 3.28 3.42 8.814 68.75 11.58 11.00

14 6 160 9.787 76.34 12.86 12.224,l 9 4.01 4.17 13.14 102.48 17.27 16.4

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IS 398 Part 2 : 1996Table 3 AllIIIlinIum CODdueton, Galvanized Steel-RelnlorcedClmues 8 2 1 8 2 2 tn A-3.2)

NomIMI strandlal .. SedIonaI Total ApproDute App. . . . . . . . . . Calaalated ApproximateAlumlalum Wire Dlmaeter Ara 01 Sect onal DIameter M_ Resistance -Calculated A AIumI m Are. at 28C, Brakln.Aluminium Steel Max Load

I (2) (3) (4) ) 6) (7) (8) 9)mm2 mm mm nun mm2 mm kglkm Ohmlkm kN10 611 5 I/l SO 10.60 12.37 4 S0 43 2.780 3.9718 611 96 1 1 96 18.10 21.12 S 88 73 1.618 6.7420 612 11 112 11 20.98 24.48 6.33 8S 1.394 7.6130 612.59 112 59 31.61 36.88 7.77 128 0.928 9 11.1250 613 35 113 35 S2 88 61.70 1 OS 214 0.552 4 11.2580 614 09 1 4 09 78.83 91.97 12.27 319 0.371 2 26.91100 614 72 7 1 57 105.0 I I I . ~ 14.IS 394 0.279 2 32.41ISO 300.59 7f2 S9 ISS.I 194.9 18.13 726 0.187 I 67.34200 3 13 713 212.1 261.5 21.00 974 0.139 0 89.67400 4213 5 7 1 96 404.1 425.2 26.88 1281 0.073 II 88.79420 5413 18 713 18 428.9 484.5 28.62 1621 0.068 68 130.32520 5414 13 7 3 53 528.5 597.0 31.77 1998 O.OSS 95 159.60560 42/4.13 712 3 562.7 591.7 31.68 1781 0.052 31 120.16

NOTE- For the bais of calculation of this table (. w Annex A).I) The sectional area is the sum of the cross-sectional areas of the relevant individual wires

Table 4 Lay Ratios 01 Aluminium Conductors, Galvanized Steel-ReinforcedClauses 10.2, 10.3 and 13.8Number 01Wires

J u m i R i ~ Sai

I (2)

1b,Io of Lay Ratios Lay Ratios for ~ u n u WireAluminium for . . Wire Steel Core Outennost Layer hnmediately Innermost Layer ofDIameter (6 Wire Layer Beneath Outermost Conductors withto Steel Layer) Layer 3 AluminiumWire DIameter Min M u Min MilX Mit MtlX Min MtlX3) 4) (6) 7) 8) 9) (10) (11)

663042S4

17777

1.03.01.01.81.0

13131313

28282828

1010101010

1414141414101010

161616 1010 1717NOTE - For the purpose of calculation the meen lay ratio shall be taken as the arithmetic mean of the relevant minimumand maximum values Jiven in this table

Table 5 Standing ConstantsTable I and Clauses 13.6. A-2.r A-2.2 and A-2.3.1)Num.her of Wires In Conductor Mass Strandin. Constant,- r l A . , Electrical ResistanceAluminium Steel A umlnlUln SteelI (2) (3) (4)6 0 6.091 1.000 0.169 26 7 6.091 7.032 0.169 230 7 30.67 7.032 0.034 0842 7 42.90 7.032 0.024 327 55.23 7.012 0.018 94

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IS 398 Part 2 : 1996

A 2.3 In calculating the stranding constants in Table5. the mean lay ratio, that is, the arithmetic meanof the relevant minimum and maximum values inTable 4. has been assumed for each layer.A-3 CALCULATED BREAKING LOAD OFCONDUCTOR

A-I.I When straightened out, each wire in anyparticular layer of standard conductor, except thecenttal wire. is longer than the stranded conductorbyan amount depending on the lay ratio of that layer.

ANNEX ATable 3)NOTES ON CALCULATION OF RESISTANCE, MASS AND B RE AK IN G L OA D

A-I INCREASE IN LENGTH DUE TOSTRANDING

A 2 RESISTANCE AND MASS OFCONDUCTORA-2.1 In aluminiwn conductors, steel reinforced theconductivity of the steel core is neglected and theresistance of the conductor is calculated withreferenceto the resistance of the aluminium wires only. Theresistance of any length of stranded conductor is theresistance of the same length of anyone aluminiumwire multiplied by a constant, as set out in Table 5.A 2.2 The mass of each wire in a length of strandedconductor, except the central wire, will be greaterthan that of an equal length of straight wire by anamount depending on the lay ratio of the layersee A-I.I). The total mass of any length of conductoris, therefore, obtained by multiplying the mass of anequal length of straight wire by the approximateconstant set out in Table 5. The masses of the steelcore and aluminium wires are calculated separatelyand added together.

A-3.t The breaking load of an aluminium conductorgalvanized steel, reinforced in terms of the sum ofthe strength of the individual component wires, maybe taken to be as follows:a) 98 percent of the sum of the breaking loads ofthe aluminium wires plus 89 percent of the sumof the breaking loads of the galvanized steelwires, when taken from the stranded conductor

and tested; orb) 98 percent of the sum of the breaking loads ofthe aluminium wires plus 85 percent of the sumof the breakingloadsof the galvanizedsteel wires,based on the breaking loads of the componentwires before stranding, that is, in the coil.A 3.2 The values of approximate breaking load ofconductors. given in Table 3 have been calculatedin accordance with b) above and on the basis ofthe minimum breaking loads of the component wiresgiven in Table I and 2.

ANNEX BForewordMODULUS OF ELASTICITY AND COEmCIENT OF LINEAR EXPANSION

No Wires Final Modulus Coefficient Linearr Elasticity Practical Expansion / CAluminium Steel GN/m21 2 3) 4)6 I 79 19.J x 106 7 75 19.8 x 10 (\30 7 80 17.8 X 1 1942 7 62 21.5 x 1054 7 69 19.3 x 10 \

NOTES1 These values are given for infonnation only.2 Moduli values quoted may be regarded as being accurate to within 3 GN/m .3 Moduli values quoted may be taken as applying to conductors stressed between 15 and 50 percent of the ultimate strengthof the conductor.4 Coefficients o f lineAl expansion have been calculated from the final pmctical) l1Xluli for the aluminium and steel componentsof the conductorsand coefficientsof linearexpansion of 23.0 x I )-6nnd II 5 ) I I C for aluminiuln and steel respectively.ANNEX CClause 6.1.2

CHEMICAL COMPOSITION OF HIGH CARBON STEELCl The chemical composition of high carbon steelused in the manufacture of steel wire of ACSRconductor is given below for guidance:

Element Percentage CompositionCarbon

0.50 to 0.85

lementManganesePhosphorusSulphurSilicon

Percentage Compositior0.50 to I. 10Max to 0.035 x 0.0450.10 to 0.35

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