IEEE – VTS 2014
PROOF POSITIVE® Copper
Design 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.
10 Year Historical Graph
of Copper & Aluminum Data
•Differential cost of $3.00/lb between copper and aluminum
Manufacturing Costs – Power Cable
3c 15kV Shielded
Labor & Packaging – 8%
12%
Jackets
Armor
Profit – 0%
we don’t want to make money
we just love to sell cable.
60%
20% Conductors
Insulation
Shields
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
Coeffiecnt of Thermal Expansion
25
20
15
10
5
0
Steel
Brass
Copper
Aluminum
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 Reliable
Aluminum 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 AA8000 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 Association
AA8000 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 Reliable
Aluminum 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 and
Aluminum Conduit Fill, 600 Volt
Cu Size
Amps
EMT
Size
Al Size
Amps
EMT
Size
1/0
150
2
3/0
155
2
2/0
175
2
4/0
180
2
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 ground
Ampacity – Table 310.15(B)(16) @75C; 30C ambient.
Comparison of Copper and
Aluminum Conduit Fill, 5kv
Cu Size
Cu
OD
Amps
Rigid
Size
Al Size
Al OD
Amps
Rigid
Size
#2
.99
150
3
1/0
1.04
150
3
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
250kcmil
1.28
330
4
500kcmil
1.47
385
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
Conduit fill is based on 3 phase with equipment ground size per NEC.
All Conduit Sizes are Metal Rigid
Ampacity 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 and
Aluminum Conduit Fill, 15kv
Cu Size
Cu
OD
Amps
Rigid
Size
Al Size
Al OD
Amps
Rigid
Size
#2
.99
150
3
1/0
1.04
150
3
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
250kcmil
1.28
330
4
500kcmil
1.47
385
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
Conduit fill is based on 3 phase with equipment ground size per NEC.
All Conduit Sizes are Metal Rigid
Ampacity 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
Impedance at 75C 60 Hz, 600 volt ohms/1,000’

4/0
:
250kcmil:
350kcmil:
500kcmil:
750kcmil:

0.067 + j 0.041 ;
0.057 + j 0.041 ;
0.043 + j 0.040 ;
0.032 + j 0.039 ;
0.024 + j 0.038 ;
z = 0.078
z = 0.070
z = 0.058
z = 0.048
z = 0.040
Source: Table 9 of NEC
ALUMINUM
Impedance at 75C 60 Hz, 600v ohms/1,000’

350kcmil: 0.066 + j 0.040 ;
500kcmil: 0.048 + j 0.039 ;
600kcmil: 0.041 + j 0.039 ;
750kcmil: 0.034 + j 0.038 ;
1000kcmil: 0.027 + j 0.037 ;

z = 0.077
z = 0.061
z = 0.055
z = 0.049
z = 0.042
Copper and Aluminum
Comparison for 5 and 15kv
COPPER
ALUMINUM

Heavier
500kcmil strd: 1,544lb/1,000’


Better Conductivity per size – dc Ohms
500kcmil = .0216 ohms/1,000’

Impedance at 75C 60 Hz in Magnetic duct 5 &
15kv ohms/1,000’
4/0
: 0.0650 + j 0.0583 ; z = 0.0873
250kcmil: 0.0557 + j 0.0570 ; z = 0.0797
350kcmil: 0.0386 + j 0.0562 ; z = 0.0681
500kcmil: 0.0300 + j 0.0526 ; z = 0.0605
750kcmil: 0.0223 + j 0.0497 ; z = 0.0545


Source: IEEE 141 - 1993
Lighter – 54% lighter
750kcmil strd: 704lb/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’
350kcmil: 0.0614 + j 0.0468 ; z = 0.0773
500kcmil: 0.0435 + j 0.0444 ; z = 0.0624
600kcmil: 0.0366 + j 0.0431 ; z = 0.0566
750kcmil: 0.0298 + j 0.0419 ; z = 0.0514
1000kcmil: 0.0233 + j 0.0414 ; z = 0.0475
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 For
Aluminum Conductors
• Disrupt surface contaminant films with steel brush
Unused aluminum strand
surfaces before brushing.
Unused aluminum strand
surfaces after brushing.
Connection Preparation
• 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.
Flexibility
• Alloying and annealing processes make AA8176 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
Force lbs
806
128
250 Al
748
197.4
3/0 Cu
750 Al
XHHW
500 Cu
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 fric
500kcmil Cu
4000 lbs
1544
8,639
750kcmil Al
4500 lbs
704
21,307
For any given route, the pulling tension on copper conductor
cables 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 America
Decatur, IN
28,000
14,000
2007
3/c 750kcmil 15kv aia
3/c 750kcmil 600v aia
$735,000
Bloomingburg Ethanol Plant
Bloomingburg, OH
16,000
12,000
2008
1/c 750kcmil 5kv
1/c 500kcmil 5kv
$110,000
Gastonia Water Treatment
Concord, 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, IL
Chrysler – Sterling Hts, MI
Chrysler – Kokomo, IN
80,000
50,000
40,000
2011,
2012
3/c 750kcmil 600v aia
3/c 750kcmil 600v aia
3/c 750kcmil 600v aia
$4,500,000
MV Power Cable Schematic
Conductor
Conductor Shield
Insulation
Insulation Shield
Metallic Shield
Jacket
Applications: Used to distribute power to: pumps, presses, motors, lighting
and control circuits etc. in: pulp & paper mills, steel mills, processing plants,
commercial centers, mines, generating stations, refineries, industrial plants
and chemical plants.
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 App’s for iPhone®, iPad®, & Android™
Southwire® Order Tracker Southwire’s Order Tracker app allows the user to view order shipments, including line status and carrier information. 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 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. Conduit Fill Answers the question: "What size conduit do I use with fill percentage and jam probability." per the NEC®. Results can be 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 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