SPECIFICATION PUBLIC

Title: PHASE CONDUCTOR FOR Unique Identifier: TSP41-264

TRANSMISSION LINES
Document Type: SPECIFICATION

Revision: 0

Effective date: NOVEMBER 2006

Total pages: 13

Review date: NOVEMBER 2009

CONTENTS PAGE

1 Scope ................................................................................................................................................... 2
2 References .......................................................................................................................................... 2
3 Definitions ............................................................................................................................................ 2
4 Requirements ...................................................................................................................................... 3
4.1 General ......................................................................................................................................... 3
4.1.1 Standard drum sizes .............................................................................................................. 3
4.2 Fabrication .................................................................................................................................... 3
4.3 Matched set requirements ............................................................................................................ 4
4.4 Length ........................................................................................................................................... 4
5 Test Requirements ............................................................................................................................ 45
6 Packaging and marking requirements ................................................................................................ 5
6.1 Drums............................................................................................................................................ 5
6.2 Marking ....................................................................................................................................... 56
ANNEXURE A Example of Technical Schedule A and B ................................................................... 7
ANNEXURE B Typical drum sizes for overhead conductor ................................................................ 8
ANNEXURE C Conductor Strand Marking .......................................................................................... 9
ANNEXURE D Typical Characteristics of Proposed Greases .......................................................... 10
ANNEXURE E Typical size wooden drum showing Eskom branded flange..................................... 11

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1 Scope
This specification covers the technical requirements for aluminium conductor with steel
reinforcement (ACSR), all aluminium alloy conductor (AAAC) and all aluminium conductor
(AAC) for use on Eskom's overhead power transmission lines.

2 References
The following documents contain provisions that, through reference in the text, constitute requirements
of this specification.

IEC 61089: 1991, Round wire concentric lay overhead electrical stranded conductors

IEC 60888: 1987, Zinc-coated steel wires for stranded conductors

IEC 60889: 1987, Hard-drawn aluminium wire for overhead line conductors

IEC 61394: 1997, Characteristics of greases for aluminium, aluminium alloy and steel bare
conductors

SANS10005: The Preservative treatment of timber

3 Definitions
3.1.1 All aluminium alloy conductors (AAAC) A conductor comprising helically wound aluminium
alloy wire.

3.1.2 All aluminium conductors (AAC): A conductor comprising helically wound hard drawn
aluminium wire.

3.1.3 Aluminium conductor, steel reinforced (ACSR): A conductor comprising hard-drawn

aluminium strands helically wound around steel reinforcing strands.

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4 Requirements
4.1 General

Nothing in this specification shall lessen the obligations of the supplier detailed in any other
specifications or documents forming part of the order.

The supplier shall be responsible for all aspects of quality, relating to manufacture, handling ,
packaging and transportation of his product.

Eskom will provide the technical detail for the required conductor as per Schedule A in ANNEXURE A.
The Supplier shall provide the details of the conductor offered in Schedule B. Any deviation from the
requirements shall be entered separately in a non-compliance statement.

4.1.1 Standard drum sizes

For non-returnable wooden drums, Table 1 in ANNEXURE B, provide guidelines on the

typical dimensions to which the drums must conform.

4.2 Fabrication

4.2.1 Each wire shall be marked with two uniform longitudinal indentations, situated 180°
opposed, along its entire length. A deviation angle of 5 to 15 degrees below 180° shall be
allowed to ensure proper contact between indent ring and wire. The dimension of the indent
mark shall be 0,3mm wide and the groove depth from 0,15mm down to 0,11 mm. The
marking rollers shall undergo periodic dimension checking to ensure that the marking groove
dimensions are within the specified limits (ANNEXURE C).The indentations shall be
performed after the wire drawing process, but before stranding. The indentations shall be
clearly visible and shall not affect the original wire characteristics, distort the wire roundness
or leave any sharp protrusions. The marking is protected by patent laws and shall therefore
be unique to and accepted by Eskom, prior to the first production run.

4.2.2 The location of all welds in individual aluminium wires shall be recorded. Copies of
these records shall be forwarded to Eskom at the time of conductor dispatch.

4.2.3 Not withstanding clause 5.5 of IEC 61089,

a) There shall be no joint in any individual wire of a steel core containing less than seven
wires.

b) Joints in individual wires of a steel core containing seven wires or more shall be
permitted, provided that

1) no two such joints are less than 15 m apart;

2) each joint is made by resistance butt welding and is protected against corrosion by
re-galvanizing; and

3) the diameter of the stranded core is not increased materially by the joint.

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4.2.4 The wire shall be so stranded that the conductor is essentially free from the tendency
to untwist or spring apart when cut.

4.2.5 The completed conductor shall be uniformly cylindrical and shall be capable of
withstanding normal handling during manufacturing, transportation, and installing without
being deformed from its cylindrical form in such a way as to increase corona losses and radio
interference.

4.2.6 When specified in the schedule of requirements, the core and the inner layers of
aluminium shall be greased with Castrol BJ20(see ANNEXURE D for typical characteristics)
or other approved grease, certified and tested in accordance with IEC 61394. The test
certificate of the grease to be used shall be supplied with the tender. The method of
application of the grease shall be as per IEC 61089 Case 4. Grease shall be uniformly
applied by a method approved by Eskom.

4.3 Matched set requirements

4.3.1 Matched sets of conductors shall be furnished in lengths given in schedule A. Matched
pairs shall be manufactured from a single length of steel core. Matched sets of four and six
conductors shall consist of two or three matched pairs respectively. All the core wire for the
matched set shall be produced from steel wires drawn from billets produced from one cast or
heat.

4.3.2 All lengths of steel core used for a matched set shall be produced on the same
strander. Each drum of the matched set of conductors shall be produced on the same
strander. Lay gears and tooling set up, shall remain constant for each production run. Lay
ratios shall not vary by more than 5 % over the entire order from a specific supplier.

4.4 Length

The length of conductor on a drum shall not vary by more than +2 % and 0 % from the
nominal length.
The variation in length between conductors forming a matched set shall not exceed 20 m.
Only one continuous length of conductor per drum shall be permitted.

5 Test Requirements
5.1 Type, sample production and routine production tests shall be carried out by the supplier,
and shall be submitted to Eskom within 7 days.

5.2 A complete set of conductor type tests certificates, in accordance with IEC 61089, must
be submitted for at least one conductor per design type at tender stage. This set of type
tests will qualify the design range at tender stage. Before a conductor is supplied to
Eskom, a full set of type tests for the conductor must be submitted.

5.3 The tenderer shall provide Eskom with an estimate of the creep each conductor
can expect over a 20-year lifespan. The estimate must be given with full details of the
calculation thereof.

5.4 All conductors which deviate from the specification or these schedules will be rejected.
Should deviations from the specification be unavoidable, written acceptance of those
deviations shall be obtained from Eskom.

5.5 Test certificates showing results of production routine tests, shall be retained by the supplier for a
minimum of five years, whereas test certificates showing results of type tests shall be retained on
permanent record by the supplier, for Eskom's inspection.
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6 Packaging and marking requirements

6.1 Drums

6.1.1 All conductors shall be supplied on returnable steel drums or non-returnable wooden
drums as specified in Schedule A.

6.1.2 For multi-layered construction the conductor shall be wound onto the drums to form
complete layers. Each layer shall fill the width of the drum before the succeeding layer is
wound on. Drums not wound in this manner will be rejected.

6.1.3 An acceptable method of holding the conductor end shall be used, to ensure that no
relative movement of conductor occurs between the uppermost uncompleted layer and the
completed layer directly below it, during transportation. Details of the proposed holding
method shall accompany the tender offer, and shall be subject to Eskom's approval.

6.1.4 Weatherproof heavy paper, cardboard or other suitable material shall be placed
between the conductor and barrel and flange surfaces of drums. This material shall
remain attached to the drum during unreeling.

6.1.5 Wood lagging shall be used to protect the conductor. Four steel straps shall be used
to secure the lagging on steel drums. Wooden lagging should be uniformly spaced
with at most 10mm spacing between adjacent lagging. The battens shall be nailed to
the flanges of wooden drums and two steel band straps shall be provided around
each drum to prevent easy removal of the battens. The length of the nails used shall
be at least 10 mm less than the distance from the outside of the battens to the top of
the conductor on the drum. Care shall be taken to prevent the nails from protruding
through the surface of the flange.

6.1.6 The moisture content of wood used for the fabrication of drums and reels shall not
exceed 150g/kg(15%).

6.1.7 Wooden drums shall have been impregnated (by pressure or in a hot/cold open tank),
in accordance with SANS 10005, with a class C preservative or with chromated
copper arsenate or similar to prevent biological attack. The preservative used shall
not react with the metal of the conductor.

6.1.8 For wood prone to superficial mould, a mouldicide should be applied to prevent mould
attack.

6.1.9 Imported conductor shall have a waterproof plastic or canvas material inserted
between the outer most layers of conductor and wrapped over the outermost layer.

6.2 Marking

Further to Clause 7.2 of IEC 61089 and Eskom's General Conditions of Purchase, the
following requirements shall also be met:

6.2.1 The drums for a matched set of conductors shall be marked:

1A and 1B for matched pairs;

1A, 1B and 1C for matched trips, etc.

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6.2.2 The actual measured length and nett mass of conductor shall be marked on each
drum in black stenciled lettering of 50mm height on the drum side.

6.2.3 Drums of greased conductor shall be marked "Greased with (the product name)".

6.2.4 All drum marking pertaining to a previous order shall be painted over or otherwise
satisfactorily obliterated.

6.2.5 All conductor drums destined for Eskom projects shall be branded with Eskom
signature (logo and logotype) on one of its flat sides (the flange).

The Eskom signature shall be printed in Eskom Blue or Black only on the white-
coloured background.

For metal drums and wooden drums, a portion of the flange surface shall be painted
in white to provide rectangular background on which the signature shall be printed in
Eskom Blue or Black only. The width (or height) of the white rectangular background
shall be three times the diameter of the “circle” part of the Eskom signature. The
printed Eskom signature shall appear central onto the white rectangular background
leaving a space equal to one signature “circle” on both front and back ends.

The Eskom logo printing shall be made by stencilling; taking care to complete
continuous character “O” in the name Eskom. Other equivalent techniques can be
used, once approved by Eskom.

The dimensions of complete Eskom signatures shall be a minimum length and width
(height) of 82 mm and 21 mm respectively. All other printing on the flange shall be
positioned so as to ensure a minimum clearance of one logo “circle” diameter away
from the Eskom signature. An example of a drum with the Eskom signature and
standard printing guidelines are shown in ANNEXURE E.

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ANNEXURE A Example of Technical Schedule A and B

Item Clause Description Schedule A Schedule B

1 Conductor Technical Parameters
Conductor Type and IEC Code
Conductor Overall Diameter (mm)
Area aluminium (mm²)
Area Total (mm²)
Aluminium wires (number off)/(diameter mm)
Steel wires (number off)/(diameter mm)
Conductor linear mass (kg/km)
Ultimate strength (kN)
Resistance dc @ 20 °C (ohms/km)
Modulus elasticity final (MPa)
Coefficient of linear expansion, ß, (1/°C)
Creep constant for 20 years in micro
strains or mm/m (µs or mm/m)

2 4 Requirements
4.2.1 Eskom conductor indentation markings as
required

4.2.6 Grease
- Grease Trade name Reference
- Name of Manufacturer/Supplier
- Product Classification
- All layers greased accept the outside as
per IEC61089, Case 4
- Specification and test certificate supplied
in accordance to IEC 61394

4.3 Matched Sets

- Conform to requirements as per 4.3

3 5 Type Test Requirements as per IEC 61089 Reference

- Joints in aluminium wires
- Stress-strain curves
- Breaking Strength of conductor
- Certificates supplied for all of the above
4 6 Packaging and Marking
6.1.1 Drum Type (Wood or Steel)
- Drum treatment process used
- Preservative and certificate supplied Reference
Total Length of Conductor (m)
Conductor Length per drum (m)
6.2 Marking of drum in accordance with 6.2

NOTES: The bidder shall complete Schedule B for the type(s) of Conductor offered and compliance to schedule A. Motivation of
any deviation from the requirements shall be entered separately in a non-compliance statement.

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ANNEXURE B Typical drum sizes for overhead conductor

Drum Dimensions

Type Conductor Length Flange Barrel Width Flange Spindle

Diameter Dia Dia Thick- Hole Dia
ness
(mm) (m) (mm) (mm) (mm) (mm) (mm)
ACSR 16,5 2 000 1 200 600 900 50 92
ACSR 18,1 1 500 1 200 700 900 50 92
2 000 1 300 700 900 50 92
2 500 1 450 700 800 63 92
3 000 1 600 800 900 63 92
ACSR 21 1 500 1 450 800 900 63 92
3 000 2 000 1 000 900 76 92
ACSR 23,45 1 500 1 600 800 800 63 92
3 000 2 000 1 000 900 76 92
ACSR 28,62 1 500 1 800 1 000 900 63 92
2 750 2 200 1 100 1 050 76 92
ACSR 35,55 2 000 2 135 1 070 1 220 75 92
AAC 16,3 1 000 1 000 500 650 50 92
AAC 26,5 2 000 2 000 1 000 800 76 92
AAC 38,3 1 500 2 400 1 200 900 76 92
AAAC 8,4 2 500 900 400 500 50 92
AAAC 8,9 2 500 900 400 650 50 92
AAAC 14,00 1 000 900 450 650 50 92
AAAC 22,6 2 000 1 600 800 900 63 92
AAAC 28,4 2 000 2 200 1 100 800 76 92
AAAC 17,4 2 000 1 300 700 800 50 92

Bending Factor = ACSR 35D

= AAC 30D

= AAAC 30D

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ANNEXURE C Conductor Strand Marking

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ANNEXURE D Typical Characteristics of Proposed Greases

Density at 20 °C 0.878

Oil Separation(P121-4hrs@150 °C) 0.15% Max

Drop Point °C >220°C

Worked Penetration at 25°C 265 - 295

Colour Brown

Total Film Froming Content 100%

Unworked Penetration @ 25°C 260

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ANNEXURE E Typical size wooden drum showing Eskom

branded flange

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The Eskom Signature (logo and logotype) printing guide

The Eskom Signature (logo and logotype) must be used together as a unit. The logo
(“circle”) and the logotype (the word “Eskom”) must always appear together as one
unit.

a) Colour specifications:

The corporate signature may only appear in the Eskom corporate blue or in black
or in white.

Pantone 287C
100%C + 70%M + 0%Y + 10%K

To match colours, swatches must always be used. Previously printed material must
never be used for colour matching.

b) Corporate signature isolation area:

There should always be a minimum clear area around the signature. This minimum is
equal to the full diameter of the logo (“circle”).

c) Relationship between the logo and the logotype:

The relationship between the logo and the logotype must always be followed exactly
as indicated in the graphic. The measurement between the logo (“circle”) and the
logotype (word “Eskom”) is twice the line-width of the “circle”.

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This document has been seen and accepted by:

Name Designation
R Ramnarain Senior Engineer: Trans-Africa Projects
B Jacobs Senior Engineer: Trans-Africa Projects

Revision Information

Rev Notes Date

6 October 2006
Paragraphs 4.1, 4.2.2 and 4.2.6 amended. Paragraph 4.4
changed. Par 5.2, 5.3, 6.1.6, 6.1.7, 6.1.8 and 6.2.5 added. 6.1.5
and 6.1.9, 6.2.2, 6.2.3, 6.2.4, Annexure A Amended. Annexures B,
C, D and E added. Renumber to TSP41-264.

5 November 2002
Minor text changes and reformatted

4 November 1995
Minor text changes and reformatted

3 Paragraph 5.1 added. Changes to paragraph 5.3 March 1995

2 Changes made to Table 1 November 1994
Originally issued as NWS 1830, the format and reference
number changed.

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