Engineering Specification

Electrical Networks

MESP 130400-01
TECHNICAL SPECIFICATION FOR
CATENARY WIRE HARD-DRAWN COPPER 37/2.5
181mm2

Version: 3

Issued: February 2017

Owner: Engineering Division

Approved By:

Andrew Russack

Head of Engineering (Electrical)

PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION
 ELECTRICAL NETWORKS SPECIFICATION
CATENARY WIRE HARD-DRAWN COPPER 37/2.5 181mm2

MESP 130400-01
Version: 3 Effective from: 27th February 2017
L1-CHE-SPE-019

Approval

Amendment Record

Approval Date Version Description

23/01/2015 1 Initial issue
Reference to joints has been removed. Joints are no longer
24/02/2016 2
permissible. Updated DC resistance in table.
Inclusion of item 6g to align with AS 1746-1991. Reference to
27/02/2017 3
standard AS 2505.6:2002 included.

Approving Manager: Head Engineer (Electrical) Approval Date: 27/02/2017 Next Review Date: 27/02/2020
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 ELECTRICAL NETWORKS SPECIFICATION
CATENARY WIRE HARD-DRAWN COPPER 37/2.5 181mm2

MESP 130400-01
Version: 3 Effective from: 27th February 2017
L1-CHE-SPE-019

Table of Contents

1. Purpose ............................................................................................................................. 4

2. Scope ................................................................................................................................ 4

3. Abbreviation ..................................................................................................................... 4

4. Definitions ......................................................................................................................... 4

5. References & Legislations ............................................................................................... 4

6. Material .............................................................................................................................. 5

7. Conductor Characteristics ............................................................................................... 5

8. Lay ..................................................................................................................................... 6

9. Dimensions ....................................................................................................................... 6

10. Production Test Requirements........................................................................................ 6

11. Quality Assurance ............................................................................................................ 6

12. Warranty ............................................................................................................................ 6

13. Packing ............................................................................................................................. 6

14. Delivery ............................................................................................................................. 7

Approving Manager: Head Engineer (Electrical) Approval Date: 27/02/2017 Next Review Date: 27/02/2020
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 ELECTRICAL NETWORKS SPECIFICATION
CATENARY WIRE HARD-DRAWN COPPER 37/2.5 181mm2

MESP 130400-01
Version: 3 Effective from: 27th February 2017
L1-CHE-SPE-019

1. Purpose
This document details the specification of 181 mm² hard-drawn copper Catenary Wire

2. Scope
The scope comprises the manufacture, testing, supply and delivery of 181 mm² hard-drawn
copper Catenary Wire in accordance with this specification and to the entire satisfaction of
Metro Trains Melbourne.

3. Abbreviation
GPa Gigapascal
Kg Kilogram
Km Kilometre
kN Kilonewton
mm Millimetre
MPa Megapascal

4. Definitions
Lay Ratio The ratio of the lay length to the external diameter of the
corresponding layer of wires

5. References & Legislations

AS 1391-2007 Metallic Materials Tensile Testing at Ambient Temperature
AS 1746-1991 Conductors - Bare Overhead - Hard-Drawn Copper
AS 2193-2005 Calibration and Classification of Force Measuring Systems
AS 2505.6:2002 Metallic Materials - Wire - Wrapping Test
AS 2738:2000 Copper and Copper Alloys - Compositions and Designations of
Refinery Products, Wrought Products, Ingots and Castings
AS 3822-2002 Test Methods for Bare Overhead Conductors
AS/NZS 1574-1996 Copper and Copper Alloys - Wire for Electrical Purposes
AS/NZS 2857:1996 Timber Drums for Insulated Electric Cables and Bare Conductors
AS/NZS ISO 9001 Quality Management Systems - Requirements.

Approving Manager: Head Engineer (Electrical) Approval Date: 27/02/2017 Next Review Date: 27/02/2020
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 ELECTRICAL NETWORKS SPECIFICATION
CATENARY WIRE HARD-DRAWN COPPER 37/2.5 181mm2

MESP 130400-01
Version: 3 Effective from: 27th February 2017
L1-CHE-SPE-019

6. Material
a. The chemical composition of the material used for the solid conductor shall conform
to AS 2738 alloy designation C11000 (Electrolytic tough pitch copper).
b. The maximum resistivity at 20°C is 0.017 77 µΩ.m (equivalent to a conductivity of
97% IACS).
c. The minimum Ultimate Tensile Strength is 430MPa for the individual strands of the
hard-drawn copper wire. The Ultimate Tensile Strength is given by 480-20d as per
alloy designation C11000 in AS 1574-1996.
d. The wire shall be clean, smooth and free from all defects.
e. There shall be no joints in the wire.
f. The wire density at 20°C shall be 8,890 kg/m³ plus or minus 3%.
g. All strands shall be subjected to a wrapping test in accordance with AS 2505.6:2002.
Each specimen shall be wrapped around a wire of its own diameter to form a close
helix of eight turns. Six turns shall than be unwrapped and again closely re-wrapped.
The wrapping rate shall not exceed 60 turns per minute. The wire shall show no signs
of cracks to the visible eye or breaks.

7. Conductor Characteristics
The lay ratio affects the area, mass and resistance of conductors composed of stranded
wires. The following stranding constants are multiplied with the corresponding property of a
single strand to give the overall characteristic:
• Stranding constants:
o Area: 36.34
o Mass: 37.68
• Resistance: 0.027 52

Strand Dia. Cross-sectional Mass/km (kg) Calculated breaking DC resistance/km @

(mm) area (mm²) load (kN) 20°C (ohms)

2.5 (nom) 181.6 1644 70.28 0.099 6

2.475 (-1%) 178 1611 68.88 0.101 6

The Calculated Break Load of the conductor is 90% of the sum of the strengths of the
individual strands before stranding. This is based on a minimum Ultimate Tensile Strength
of 480-20d MPa, where ‘d’ is the diameter of the strand in millimeters.
Modulus of elasticity may be taken as 108GPa. This value is obtained after the initial
stretch of the wire following construction.
Coefficient of linear expansion may be taken as 17x10-6 per °C.

Approving Manager: Head Engineer (Electrical) Approval Date: 27/02/2017 Next Review Date: 27/02/2020
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 ELECTRICAL NETWORKS SPECIFICATION
CATENARY WIRE HARD-DRAWN COPPER 37/2.5 181mm2

MESP 130400-01
Version: 3 Effective from: 27th February 2017
L1-CHE-SPE-019

8. Lay
Lay ratio and direction of the three layers shall be:
6-wire layer: 10 min, 17 max. Right-hand lay
12-wire layer: 10 min, 16 max. Left-hand lay
18-wire layer. 10 min, 16 max. Right-hand lay

9. Dimensions
Wire size and tolerances shall be in accordance with AS 1746-1991. For a 37/2.5 nominal
conductor of 181mm² nominal cross-sectional area the overall wire diameter shall be
17.5mm +/- 1%.

10. Production Test Requirements

For the purposes of this specification the metallurgical tests shall be in accordance with
AS/NZS 1574. Mechanical and electrical tests shall be in accordance with AS 1746-1991,
AS 2505.6:2002 and AS 3822.

11. Quality Assurance

The Supplier should meet the requirements of AS/NZS ISO 9001.

12. Warranty
The Supplier shall provide a ‘Certificate of Conformance’ together with a full test report as
stipulated in Production Test Requirements.

13. Packing
a) The transmission wire shall be wound without twists, or kinks, on drums of approved
design and of sufficient size to prevent sharp bends and shall be properly protected
against damage in transit.
b) Typically approved design is wooden drums lined with sisal-craft in general
accordance with AS 2857 and the following Metro Trains Melbourne required
dimensions:
o Barrel diameter 600mm minimum
o Overall diameter 1200mm maximum
o Overall width 920mm maximum
A mild steel reinforcing plate 400mm2 by 6.4mm thick shall be bolted to the middle of each
side of the drum with a minimum of 6 bolts. An 83mm square hole shall be provided in the
drum and reinforcing plates to take a 76mm spindle.
The free ends of the wire shall be suitably treated to prevent de-stranding. The inner end of
the conductor shall be passed through the drum flange to the outside and stapled securely.
The outer end of the conductor shall be secured to the inside of the drum flange with
staples and bent back on itself to prevent it from working loose.

Approving Manager: Head Engineer (Electrical) Approval Date: 27/02/2017 Next Review Date: 27/02/2020
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 ELECTRICAL NETWORKS SPECIFICATION
CATENARY WIRE HARD-DRAWN COPPER 37/2.5 181mm2

MESP 130400-01
Version: 3 Effective from: 27th February 2017
L1-CHE-SPE-019

c) Metro Trains Melbourne shall specify the length of the conductor on each drum.
d) The following information shall be legibly and indelibly marked on the flange of the
drums or a label securely attached thereto:
(i) Supplier’s name
(ii) Supplier’s drum serial number
(iii) The conductor material and size (Hard-drawn copper, catenary wire 37/2.5,
181mm2)
(iv) Length of conductor
(v) Gross mass of conductor and drum
(vi) Handling or lifting instructions. The preferred method being by means of a
spindle through the spindle holes and a spreader to prevent damage to the
flanges
(vii) An arrow with the words 'ROLL THIS WAY' to indicate the direction in which
the drum should be rolled on the flanges
(viii) The Metro Trains Melbourne contract number, order number and specification
number
e) Alternative equivalent or superior packing system may be submitted to Metro Trains
Melbourne for consideration.

14. Delivery
Transmission wires shall be delivered free into Metro Trains Melbourne Central Store. The
Central Store is located at E-Gate, Footscray Road, West Melbourne, Victoria 3051 and
delivery shall take place during business hours Monday to Friday (except Public Holidays)
from 0800 till 1530. Metro Trains Melbourne shall be notified of any delivery 5-working
days prior to delivery.

Approving Manager: Head Engineer (Electrical) Approval Date: 27/02/2017 Next Review Date: 27/02/2020
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