Product Details

Product Range
Cable Type Specifications

1) AAA Conductors upto 1.1KV Power,

    IS:398 (Part IV)- 1994 

-Upto 61 Strands

-Aluminium Conductor

About the Conductor

AAA (All Aluminium Alloy) Conductor is made from aluminum-magnesium-silicon alloy of high electrical conductivity containing Magnesium (0.6-0.9%)  &  Silicon (0.5-0.9%) to give i better mechanical properties after treatment.

AAA conductors are generall made out of aluminum alloy 6201 (Minimum Conductivity is 54%). AAA Conductor has a better corrosion resistance and better strength to weight ratio and improved electrical conductivity than ACSR Conductor on equal diameter basis.

Advantages of AAA conductor over ACSR Conductor is as follows:

Corrosion Resistance

AAA exhibits excellent corrosion resistances specially in sea coast areas and in polluted industrial area due to absence of steel core.

Lower Power Losses

Since AAA is homogeneous ( with all strands of Aluminium Alloy) with no steel component the resistance of AAAC is lower as compared to ACSR.

Higher Ampacity

AAA can carry at least 15-20% extra current as compared to ACSR of equal size.

Longer Life

Experience in foreign countries shows that All Aluminium Alloy Conductors are in service for over 60 years, which is about double the life of Acsr Conductors.

Surface Hardness

The surface hardness of AAA is 80 Bhn as compared to 35 Bhn of ACSR.This reduces the damage to surface during handling and therefore leading to lesser corona losses and ratio interference at EHV.

Thermal Stability

AAA are stable up to 90ºC against ACSR Conductor which are Stable up to 75ºC.

Higher Strength to Weight Ratio

Since AAA has higher Strength to weight ratio, spam can be increased from 2 to 15% resulting in overall reduction of cost in towers supports and other accessories in transmission line system.
Application

AAA conductors are most commonly used by power distributing companies:

  • LT Transmission
  • HT Transmission
General Construction

There are two methods which are adopted:-

  • Almelec Process: In this process Aluminum Alloy Wire Rod (9.6mm) is first drawn into a intermediate size of 6mm diameter. The wire than is solution treated and after a gap of about 24-48 hours is then drawn to the required size which is finally aged and stranded.
  • Aldrey Process: In this process the Aluminium Alloy Wire Rod is directly solution treated and then directly drawn in required size and finally aged to obtain desired properties and stranded.

NOTE: We adopt Almelec Process of France for manufacturing of AAA Conductor.

Solution Treatment

In this process the 6mm alloy wire is charged in an electrically heat and air circulating solution treatment furnace. This is then heated at a temperature of 5400C (+50C)with boiling time of 60-90 minutes and thereafter immediately(within 30 sec.) quenched in water. Then wire is kept in open for drying at room temperature.

This process is by which super saturated solid solution of alloy structure is produced to take advantages of its precipitation hardening chracterstics. 

Drawing

The 6mm wire after being solution treated and cooled for a mimimum of 24 hours (max. 72hrs) is then drawn into the required size in Slip-type Wire drawing machines and wound in spools.

Ageing Treatment

Artifical ageing is the heat treatment to stabilizethe structure of alloy wire at desired hardness. The wire accomated in spools are then charged in electrically heatedfurnace for a period of 6-8 hrs at a temperature between 140-1800C.

 
Stranding

In case of Small Conductors i.e Conductors not having more than seven strands, all the seven spools of Aluminium alloy wire after aging is stranded in Tubular Machine with proper pre-forming and post-forming.

In case of Multi Layer Conductor, seven Aluminium Alloy Wire are stranded in Tubular Machine and the same stranded wire is again stranded with more 54 Alloy wire in Multi Strand Machine and then wound in the required Wooden Drum. Packing & stencling is done as per IS-398 Part – 4.

Technical Specifications

All Aluminium Alloy Stranded Conductors as Per IS 398 PART IV /1994

Sl.No. Actual Area Stranding And Wire Diameter Approx. Overall Diameter Approx. Mass Calculated Maximum Resistance At 20ºC Approx. Calculated Breaking Load
mm² mm mm Kg/Km. Ohms/Km. KN
1 15 3/2.50 5.39 4015.00 2.304 4.33
2 22 7.2.00 6.00 60.16 1.5410 6.45
3 34 7/2.50 7.50 94.00 0.9900 10.11
4 55 7/3.15 9.45 149.20 0.6210 16.03
5 80 7/3.81 11.43 218.26 0.4250 23.41
6 100 7/4.26 12.78 272.86 0.339 29.26
7 125 19/2.89 14.45 342.51 0.2735 36.64
8 148 19/3.15 15.75 406.91 0.229 43.5
9 173 19/3.40 17.00 474.02 0.1969 50.54
10 200 19/3.66 18.30 549.40 0.171 58.66
11 232 19/3.94 19.70 636.67 0.1471 68.05
12 288 36/3.50 22.05 794.05 0.1182 84.71
13 346 37.3.45 24.15 952.56 0.0984 101.58
14 400 37/3.71 25.97 1101.63 0.0829 117.4
15 465 37/4.00 28.00 1280.50 0.0734 136.38
16 525 61/3.31 28.79 1448.39 0.0651 146.03
17 570 61/3.45 31.05 1573.71 0.0598 158.66
18 604 61/3.55 31.95 1666.00 0.0568 176.99
19 642 61/3.66 32.94 1771.36 0.0534 178.43
20 695 61/3.81 34.29 1919.13 0.0492 193.25
21 767 61/4.00 36.00 2915.54 0.0446 213.01